SUZUKI GSX-R600 Manuals

Manuals and User Guides for SUZUKI GSX-R600. We have 3 SUZUKI GSX-R600 manuals available for free PDF download: Manual, Service Manual

suzuki GSX-R600 Manual (653 pages)

Brand: suzuki | Category: Motorcycle | Size: 21.59 MB

Section 1 Engine

63
- General Information
  13
- Cylinder Identification
  17
- Maintenance and Lubrication
  28
- Scheduled Maintenance
  28
- Lubrication Points
  29
- Front Fork Inspection
  47
- Table of Contents
  63
- Precautions
  
  68
  - Precautions for Engine
    68
- Engine General Information and Diagnosis
  
  69
- General Description
  
  69
  - Injection Timing Description
    69
  - Self-Diagnosis Function
    71
- Schematic and Routing Diagram
  
  72
  - FI System Wiring Diagram
    72
  - Terminal Alignment of ECM Coupler
    74
- Component Location
  
  75
  - FI System Parts Location
    75
- Diagnostic Information and Procedures
  
  77
- Specifications
  
  210
  - Service Data
    210
- Special Tools and Equipment
  
  211
  - Special Tool
    211
- Emission Control Devices
  
  213
- Precautions
  
  213
  - Precautions for Emission Control Devices
    213
- General Description
  
  213
- Schematic and Routing Diagram
  
  217
  - PAIR System Hose Routing Diagram
    217
  - EVAP Canister Hose Routing Diagram
    218
- Repair Instructions
  
  219
- Specifications
  
  229
  - Service Data
    229
  - Tightening Torque Specifications
    229
- Special Tools and Equipment
  
  229
  - Special Tool
    229
- Engine Electrical Devices
  
  230
- Precautions
  
  230
  - Precautions for Engine Electrical Device
    230
- Component Location
  
  230
  - Engine Electrical Components Location
    230
- Diagnostic Information and Procedures
  
  230
  - Engine Symptom Diagnosis
    230
- Repair Instructions
  
  230
  - ECM Removal and Installation
    230
  - CMP Sensor Inspection
    231
  - CMP Sensor Removal and Installation
    231
  - CKP Sensor Inspection
    232
  - CKP Sensor Removal and Installation
    232
  - IAP Sensor Inspection
    232
  - IAP Sensor Removal and Installation
    232
  - TP Sensor Inspection
    232
  - TP Sensor Removal and Installation
    232
  - TP Sensor Adjustment
    233
  - ECT Sensor Removal and Installation
    233
  - ECT Sensor Inspection
    234
  - IAT Sensor Removal and Installation
    234
  - IAT Sensor Inspection
    235
  - AP Sensor Inspection
    235
  - AP Sensor Removal and Installation
    235
  - TO Sensor Inspection
    235
  - TO Sensor Removal and Installation
    235
  - STP Sensor Inspection
    236
  - STP Sensor Adjustment
    236
  - STP Sensor Removal and Installation
    237
  - STV Actuator Inspection
    237
  - STV Actuator Removal and Installation
    237
  - ISC Valve Inspection
    237
  - ISC Valve Removal and Installation
    237
  - ISC Valve Preset and Opening Initialization
    238
  - HO2 Sensor Inspection
    238
  - HO2 Sensor Removal and Installation
    238
  - GP Switch Inspection
    238
  - GP Switch Removal and Installation
    238
- Specifications
  
  239
  - Service Data
    239
  - Tightening Torque Specifications
    239
- Special Tools and Equipment
  
  240
  - Special Tool
    240
- Engine Mechanical
  
  241
- Schematic and Routing Diagram
  
  241
  - Camshaft and Sprocket Assembly Diagram
    241
  - Throttle Cable Routing Diagram
    242
- Diagnostic Information and Procedures
  
  243
  - Engine Mechanical Symptom Diagnosis
    243
  - Compression Pressure Check
    243
- Repair Instructions
  
  244
  - Engine Components Removable with the Engine in Place
    244
  - Air Cleaner Element Removal and Installation
    246
  - Air Cleaner Box Removal and Installation
    247
  - Air Cleaner Element Inspection and Cleaning
    247
  - Throttle Cable Removal and Installation
    247
  - Throttle Cable Inspection
    247
  - Throttle Cable Play Inspection and Adjustment
    247
  - Throttle Body Components
    248
  - Throttle Body Construction
    249
  - Throttle Body Removal and Installation
    250
  - Throttle Body Disassembly and Assembly
    251
  - Throttle Body Inspection and Cleaning
    255
  - ISC Valve Visual Inspection
    256
  - Throttle Valve Synchronization
    256
  - ISC Valve Reset
    258
  - TP Reset
    258
  - Engine Assembly Removal
    259
  - Engine Assembly Installation
    263
  - Engine Top Side Disassembly
    265
  - Engine Top Side Assembly
    267
  - Camshaft Inspection
    274
  - Camshaft Sprocket
    276
  - Cam Chain Tension Adjuster Inspection
    276
  - Cam Chain Guide / Cam Chain Tensioner Removal and Installation
    277
  - Cam Chain Guide Inspection
    277
  - Cam Chain Tensioner Inspection
    277
  - Cylinder Head Disassembly and Assembly
    278
  - Cylinder Head Related Parts Inspection
    282
  - Valve Guide Replacement
    285
  - Valve Seat Repair
    287
  - Engine Bottom Side Disassembly
    287
  - Engine Bottom Side Assembly
    294
  - Cylinder Inspection
    309
  - Piston Ring Removal and Installation
    309
  - Piston and Piston Ring Inspection
    311
  - Conrod Crank Pin Bearing Removal and Installation
    313
  - Conrod and Crankshaft Inspection
    313
  - Conrod Crank Pin Bearing Inspection and Selection
    314
  - Crankshaft Journal Bearing Inspection and Selection
    316
  - Crankshaft Thrust Clearance Inspection and Selection
    319
- Specifications
  
  321
  - Service Data
    321
  - Tightening Torque Specifications
    323
- Special Tools and Equipment
  
  324
  - Recommended Service Material
    324
  - Special Tool
    324
- Engine Lubrication System
  
  327
- Precautions
  
  327
  - Precautions for Engine Oil
    327
- Schematic and Routing Diagram
  
  328
  - Engine Lubrication System Chart Diagram
    328
  - Oil Pan
    328
  - Engine Lubrication Circuit Diagram
    329
- Diagnostic Information and Procedures
  
  331
  - Engine Lubrication Symptom Diagnosis
    331
  - Oil Pressure Check
    331
- Repair Instructions
  
  332
- Specifications
  
  340
  - Service Data
    340
  - Tightening Torque Specifications
    341
- Special Tools and Equipment
  
  341
  - Recommended Service Material
    341
  - Special Tool
    341
- Engine Cooling System
  
  342
- Precautions
  
  342
  - Precautions for Engine Cooling System
    342
  - Precautions for Engine Coolant
    342
- General Description
  
  342
  - Engine Coolant Description
    342
- Schematic and Routing Diagram
  
  343
  - Cooling Circuit Diagram
    343
  - Water Hose Routing Diagram
    344
- Diagnostic Information and Procedures
  
  345
  - Engine Cooling Symptom Diagnosis
    345
- Repair Instructions
  
  345
  - Cooling Circuit Inspection
    345
  - Radiator Cap Inspection
    346
  - Radiator Inspection and Cleaning
    346
  - Radiator / Cooling Fan Motor Removal and Installation
    346
  - Water Hose Inspection
    347
  - Water Hose Removal and Installation
    348
  - Radiator Reservoir Tank Inspection
    348
  - Radiator Reservoir Tank Removal and Installation
    349
  - Cooling Fan Inspection
    349
  - Cooling Fan Relay Inspection
    349
  - ECT Sensor Removal and Installation
    350
  - ECT Sensor Inspection
    350
  - Thermostat Removal and Installation
    350
  - Thermostat Inspection
    351
  - Water Pump Components
    352
  - Water Pump Construction
    353
  - Water Pump Removal and Installation
    353
  - Water Pump Disassembly and Assembly
    354
  - Water Pump Related Parts Inspection
    357
- Specifications
  
  359
  - Service Data
    359
  - Tightening Torque Specifications
    359
- Special Tools and Equipment
  
  360
  - Recommended Service Material
    360
  - Special Tool
    360
- Fuel System
  
  361
- Precautions
  
  361
  - Precautions for Fuel System
    361
- General Description
  
  362
  - Fuel Injection System Description
    362
- Schematic and Routing Diagram
  
  363
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram
    363
- Diagnostic Information and Procedures
  
  364
  - Fuel System Diagnosis
    364
- Repair Instructions
  
  365
  - Fuel Pressure Inspection
    365
  - Fuel Pump Inspection
    365
  - Fuel Discharge Amount Inspection
    366
  - Fuel Pump Relay Inspection
    367
  - Fuel Hose Inspection
    367
  - Fuel Level Gauge Inspection
    367
  - Fuel Tank Construction
    368
  - Fuel Tank Removal and Installation
    369
  - Fuel Pump Components
    370
  - Fuel Pump Disassembly and Assembly
    371
  - Fuel Mesh Filter Inspection and Cleaning
    373
  - Fuel Injector / Fuel Delivery Pipe / T-Joint Removal and Installation
    373
  - Fuel Injector Inspection and Cleaning
    373
- Specifications
  
  374
- Special Tools and Equipment
  
  375
  - Recommended Service Material
    375
  - Special Tool
    375
- Ignition System
  
  376
- General Description
  
  376
  - Immobilizer Description (for
    376
  - Drive Mode Selector Description
    377
- Schematic and Routing Diagram
  
  378
  - Ignition System Diagram
    378
  - Ignition System Components Location
    378
- Diagnostic Information and Procedures
  
  379
  - Ignition System Symptom Diagnosis
    379
  - No Spark or Poor Spark
    380
- Repair Instructions
  
  381
- Specifications
  
  388
  - Service Data
    388
  - Tightening Torque Specifications
    388
- Special Tools and Equipment
  
  389
  - Recommended Service Material
    389
  - Special Tool
    389
- Starting System
  
  390
- Schematic and Routing Diagram
  
  390
  - Starting System Diagram
    390
- Component Location
  
  390
  - Starting System Components Location
    390
- Diagnostic Information and Procedures
  
  390
- Repair Instructions
  
  392
- Specifications
  
  403
  - Service Data
    403
  - Tightening Torque Specifications
    403
- Special Tools and Equipment
  
  404
  - Recommended Service Material
    404
  - Special Tool
    404
- Charging System
  
  405
- Schematic and Routing Diagram
  
  405
  - Charging System Diagram
    405
- Component Location
  
  405
  - Charging System Components Location
    405
- Diagnostic Information and Procedures
  
  405
  - Charging System Symptom Diagnosis
    405
  - Battery Runs down Quickly
    406
- Repair Instructions
  
  407
  - Battery Current Leakage Inspection
    407
  - Regulated Voltage Inspection
    407
  - Generator Inspection
    407
  - Generator Removal and Installation
    408
  - Regulator / Rectifier Construction
    412
  - Regulator / Rectifier Removal and Installation
    413
  - Regulator / Rectifier Inspection
    414
  - Battery Components
    415
  - Battery Charging
    415
  - Battery Removal and Installation
    417
  - Battery Visual Inspection
    418
- Specifications
  
  418
  - Service Data
    418
  - Tightening Torque Specifications
    418
- Special Tools and Equipment
  
  419
  - Recommended Service Material
    419
  - Special Tool
    419
- Exhaust System
  
  420
- Precautions
  
  420
  - Precautions for Exhaust System
    420
- General Description
  
  420
  - Exhaust Control System Description
    420
  - Exhaust Control System Operation
    421
- Repair Instructions
  
  423
  - Exhaust Control System Construction
    423
  - Exhaust System Components
    424
  - EXCV Cable Removal and Installation
    425
  - EXCVA Removal and Installation
    426
  - EXCVA Inspection
    428
  - EXCVA Pulley Inspection
    428
  - EXCVA Adjustment
    428
Section 2 Suspension

435
- Precautions
  
  436
  - Precautions for Suspension
    436
- Suspension General Diagnosis
  
  437
- Diagnostic Information and Procedures
  
  437
  - Suspension and Wheel Symptom Diagnosis
    437
- Repair Instructions
  
  438
  - Front Fork Components
    438
  - Front Fork Removal and Installation
    439
  - Front Suspension Adjustment
    441
  - Front Fork Disassembly and Assembly
    441
  - Front Fork Parts Inspection
    448
- Front Suspension
  
  438
- Specifications
  
  449
  - Service Data
    449
  - Tightening Torque Specifications
    449
- Special Tools and Equipment
  
  450
  - Recommended Service Material
    450
  - Special Tool
    450
- Rear Suspension
  
  451
- Repair Instructions
  
  451
- Specifications
  
  465
  - Service Data
    465
  - Tightening Torque Specifications
    465
- Special Tools and Equipment
  
  466
  - Recommended Service Material
    466
  - Special Tool
    466
- Wheels and Tires
  
  467
- Precautions
  
  467
  - Precautions for Wheel and Tire
    467
- Repair Instructions
  
  468
- Specifications
  
  485
  - Service Data
    485
  - Tightening Torque Specifications
    485
- Special Tools and Equipment
  
  486
  - Recommended Service Material
    486
  - Special Tool
    486
Section 3 Driveline / Axle

487
- Precautions
  
  488
  - Precautions for Driveline / Axle
    488
- Diagnostic Information and Procedures
  
  489
  - Drive Chain and Sprocket Symptom Diagnosis
    489
- Repair Instructions
  
  489
- Drive Chain / Drive Train / Drive Shaft
  
  489
- Specifications
  
  498
  - Service Data
    498
  - Tightening Torque Specifications
    498
- Special Tools and Equipment
  
  499
  - Recommended Service Material
    499
  - Special Tool
    499

Suzuki GSX-R600 Service Manual (466 pages)

Brand: Suzuki | Category: Motorcycle | Size: 52.53 MB

Foreword
2
Group Index
2
How to Use this Manual
3
Component Parts and Work to be Done
3
Symbol
4
Abbreviations Used in this Manual
5
Wire Color
7
General Information
8
Contents
8
Warning/Caution/Note
9
Suzuki GSX-R600K4 ('04-Model) View
11
Serial Number Location
11
Fuel, Oil and Engine Coolant Recommendation Fuel (for USA and Canada)
12
Fuel (for Other Countries)
12
Engine Oil (for USA)
12
Engine Oil (for Other Countries)
12
Engine Coolant
13
Water for Mixing
13
Anti-Freeze/Engine Coolant
13
Liquid Amount of Water/Engine Coolant
13
Break-In Procedures
14
Cylinder Identification
14
Information Labels
15
Specifications
16
Dimensions and Dry Mass
16
Drive Train
16
Electrical
17
Capacities
17
Periodic Maintenance
18
Periodic Maintenance Schedule
19
Periodic Maintenance Chart
19
Lubrication Points
20
Maintenance and Tune-Up Procedures
21
Air Cleaner
21
Spark Plug and Ignition Coil/Plug Cap Removal
22
Heat Range
22
Carbon Deposits
22
Spark Plug Gap
23
Electrode's Condition
23
Spark Plug and Ignition Coil/Plug Cap Installation
23
Valve Clearance
24
Valve Clearance Adjustment
26
Intake Side
27
Tappet Shim Selection Table
27
Exhaust Side
28
Engine Oil and Oil Filter
29
Engine Oil Replacement
29
Oil Filter Replacement
30
Fuel Line
31
Engine Idle Speed
31
Throttle Valve Synchronization
32
Evaporative Emission Control System (E-33 Only)
32
Pair (Air Supply) System
32
Throttle Cable Play
33
Clutch
33
Cooling System
34
Engine Coolant Level Check
34
Engine Coolant Change
34
Air Bleeding the Cooling Circuit
35
Radiator Hoses
36
Drive Chain
37
Checking
37
Adjusting
38
Cleaning and Lubricating
39
Brake Fluid Level Check
40
Brake Pads
41
Front Brake
41
Rear Brake
41
Brake Pedal Height
41
Brake Light Switch
42
Air Bleeding from Brake Fluid Circuit
42
Front Brake (Caliper Side)
42
Front Brake (Master Cylinder Side)
43
Tire Tread Condition
44
Tire Pressure
44
Steering
45
Front Fork
45
Rear Suspension
45
Exhaust Pipe Bolt and Muffler Bolt and Nut
46
Chassis Bolts and Nuts
47
Compression Pressure Check
49
Compression Pressure Specification
49
Compression Test Procedure
49
Oil Pressure Check
50
Oil Pressure Specification
50
Oil Pressure Test Procedure
50
Engine
52
Engine Components Removable with Engine in Place
53
Engine Center
53
Engine Right Side
53
Engine Left Side
53
Engine Removal
54
Radiator
55
Exhaust Pipe and Muffler
56
Electric Parts and Pair Hose
57
Engine Sprocket and Gear Shift Lever
58
Engine Mounting
59
Engine Installation
61
Engine Disassembly
67
Starter Motor
67
Cylinder Head Cover and Pair Reed Valve
67
Camshafts
68
Cylinder Head
69
Oil Pump
72
Gearshift System
72
Starter Idle Gear
73
Starter Clutch
74
Cam Chain, Cam Chain Tensioner and Cam Chain Guide
74
CKP Sensor
74
Generator Cover
75
Generator Rotor
75
Water Pump
75
Gear Position Switch
76
Crankcase Breather (PCV) Cover
76
Oil Filter
76
Lower Crank Case
77
Middle Crankcase
78
Crankshaft
78
Piston and Conrod
78
Engine Components Inspection and Service
80
Cylinder Head Cover
80
CMP Sensor
80
Pair Reed Valve
80
PCV Hose
81
Camshaft Identification
81
Cam Wear
81
Camshaft Journal Wear
82
Сamshaft Runout
83
Сam Sprocket
83
Сam Chain Tension Adjuster
83
Сam Chain Tensioner
84
Сam Chain Guide
84
Сylinder Head and Valve
84
Valve and Valve Spring Disassembly
84
Cylinder Head Distortion
86
Valve Stem Runout
86
Valve Head Radial Runout
86
Valve Stem and Valve Face Wear Condition
87
Valve Stem Deflection
87
Valve Stem Wear
87
Valve Guide Servicing
88
Valve Seat Width Inspection
89
Valve Seat Servicing
90
Initial Seat Cut
90
Top Narrowing Cut
91
Bottom Narrowing Cut
91
Final Seat Cut
92
Valve Spring
93
Valve and Valve Spring Reassembly
94
Intake Pipe
95
Water Bypass Union
96
Clutch Drive Plates Inspection
96
Clutch Spring Inspection
97
Clutch Bearing Inspection
97
Clutch Sleeve Hub/Primary Driven Gear Assembly
97
Generator
98
Gearshift Shaft/Gearshift Arm Disassembly
99
Gearshift Shaft/Gearshift Arm Inspection
99
Gearshift Shaft/Gearshift Arm Reassembly
99
Oil Pressure Regulator
100
Transmission
101
Disassembly
101
Reassembly
102
Transmission Parts Location
103
Cylinder Distortion
104
Cylinder Bore
104
Piston and Piston Ring
105
Piston Diameter
105
Piston-To-Cylinder Clearance
105
Piston Pin and Pin Bore
105
Piston Ring-To-Groove Clearance
106
Piston Ring Free End Gap and Piston Ring End Gap
106
Crankcase
107
Gearshift Fork and Gearshift Cam
107
Gearshift Fork-To-Groove Clearance
107
Gearshift Fork Groove Width
107
Gearshift Fork Thickness
108
Gearshift Cam Bearing and Gearshift Shaft Bearing
108
Bearing Inspection
108
Bearing Removal
108
Installation
109
Oil Jet
111
Inspection and Cleaning
111
Plug
112
Conrod Big End Side Clearance
113
Conrod-Big End Bearing Inspection
113
Conrod-Big End Bearing Selection
113
Crankshaft and Conrod
114
Crankshaft Runout
114
Conrod Small End I.D.
114
Crank Pin O.D.
115
Bearing Thickness
115
Bearing Selection Table
116
Conrod I.D.
116
Crankshaft Journal Bearing
118
Selection
118
Crankcase I.D. Specification
119
Crankshaft Journal O.D. Specification
120
Bearing Thickness Specification
120
Crankshaft Thrust Bearing
121
Crankshaft Thrust Clearance Adjustment
121
Thrust Bearing Selection Table
122
Engine Reassembly
123
Piston Ring
123
Oil Strainer
133
Oil Pan
133
Oil Pressure Switch
134
Crankcase Breather Cover
135
Cam Chain Drive Sprocket
138
Cam Chain Tensioner and Cam Chain Guide
138
Clutch Cover
146
Camshaft
149
Cam Chain Tension Adjuster
152
FI System Diagnosis
157
Precautions in Servicing
159
Electrical Parts
159
Connector/Coupler
159
Fuse
160
Ecm/Various Sensors
160
Electrical Circuit Inspection Procedure
162
Open Circuit Check
162
Continuity Check
163
Voltage Check
163
Short Circuit Check (Wire Harness to Ground)
164
Using the Multi-Circuit Tester
165
Using the Tester
165
FI System Technical Features
166
Injection Time (Injection Volume)
166
Compensation of Injection Time (Volume)
167
Injection Stop Control
167
Injection Timing
168
FI System Parts Location
169
FI System Wiring Diagram
171
Self-Diagnosis Function
172
User Mode
172
Dealer Mode
173
TPS Adjustment
175
Fail-Safe Function
176
FI System Troubleshooting
178
Self-Diagnostic Procedures
180
Self-Diagnosis Reset Procedure
180
Malfunction Code and Defective Condition
181
"C11" CMP Sensor Circuit Malfunction
183
"C12" CKP Sensor Circuit Malfunction
185
"C13" IAP Sensor Circuit Malfunction
187
"C14" TP Sensor Circuit Malfunction
190
"C15" ECT Sensor Circuit Malfunction
191
Output Voltage
193
"C21" IAT Sensor Circuit Malfunction
195
"C22" AP Sensor Circuit Malfunction
197
"C23" to Sensor Circuit Malfunction
200
"C28" STV Actuator Circuit Malfunction
202
"C29" STP Sensor Circuit Malfunction
204
"C31" GP Switch Circuit Malfunction
207
"C32", "C33", "C34" or "C35" Fuel Injector Circuit Malfunction
208
"C41" FP Relay Circuit Malfunction
210
"C42" IG Switch Circuit Malfunction
210
"C49" Pair Control Solenoid Valve Circuit Malfunction
211
Sensors
213
Fuel System and Throttle Body
216
Fuel Delivery System
217
Fuel System
218
Fuel Tank Lift-Up
218
Fuel Tank Removal
218
Fuel Pressure Inspection
219
Fuel Pump Inspection
220
Fuel Discharge Amount Inspection
220
Fuel Pump Relay Inspection
221
Fuel Pump and Fuel Filter Removal
222
Construction
222
Fuel Mesh Filter Inspection and Cleaning
224
Fuel Pump and Fuel Mesh Filter Installation
224
Throttle Body Construction
228
Air Cleaner Box Removal
229
Throttle Body Removal
230
Throttle Body Disassembly
231
Throttle Body Cleaning
233
Throttle Body Reassembly
234
Throttle Body Installation
236
Air Cleaner Box Installation
237
STP Sensor Adjustment
237
Fuel Injector Removal
238
Fuel Injector Inspection
238
Fuel Injector Installation
238
Fast Idle Adjustment
239
Use for Digital Vacuum Tester
241
Use for Vacuum Balancer Gauge
242
Calibrating each Vacuum Gauge
242
Throttle Position Sensor (TPS) Setting
244
Exhaust System
246
Precautions for Exhaust System
247
Exhaust System Components
247
Cooling and Lubrication System
250
Cooling Circuit Inspection
252
Radiator and Water Hoses
253
Radiator Removal
253
Radiator Cap Inspection
253
Radiator Inspection and Cleaning
253
Water Hose Inspection
254
Cooling Fan
255
Cooling Fan Thermo-Switch
256
ECT Sensor
257
Temperature Sensor Specification
257
Thermostat
258
Mechanical Seal
263
Oil Seal
263
Impeller Shaft Journal
263
Seal Washer
263
Lubrication System
267
Oil Cooler
267
Engine Lubrication System Chart
269
Engine Lubrication System
270
Chassis
273
Exterior Parts
275
Fastener Removal and Reinstallation
275
Screen
276
Body Cowling Cover and Lower Bracket Cover
276
Right and Left under Cowlings
276
Body Cowling
278
Right and Left Air Intake Pipes
279
Cowling Brace
279
Front Seat
279
Rear Seat and Seat Tail Cover
280
Frame Cover
280
Front Wheel Construction
281
Axle Shaft
283
Wheel Bearing
283
Reassembly and Installation
284
Brake Disc
285
Spacer Nut
286
Brake Caliper
286
Front Axle
286
Front Fork Construction
287
Inner and Outer Tubes
291
Damper Rod
292
Compression Damping Force Adjuster
292
Oil Seal and Dust Seal
292
Damper Rod Bolt
293
Fork Oil
293
Fork Spring
294
Front Fork Cap Bolt
295
Suspension Setting
298
Spring Pre-Load Adjustment
298
Damping Force Adjustment
298
Standard Front Suspension Setting
298
Steering Damper Construction
299
Steering Construction
301
Inner Race
303
Stem Nut
304
Front Fork and Steering Stem Upper Bracket
305
Steering Tension Adjustment
306
Handlebars Construction
307
Rear Wheel Construction
311
Rear Axle
313
Wheel Damper
313
Sprocket
314
Dust Seals
317
Rear Sprocket and Sprocket Mounting Drum
317
Rear Shock Absorber Construction
319
Rear Shock Absorber Scrapping Procedure
321
Rear Shock Absorber Gas Release
321
Rear Suspension Construction
323
Spacer
326
Swingarm Bearing
326
Cushion Lever Bearing
327
Cushion Lever and Cushion Lever Rods
327
Swingarm Pivot Shaft
327

Suzuki GSX-R600 Manual (165 pages)

Brand: Suzuki | Category: Motorcycle | Size: 2.75 MB

Table of Contents

4
- The Sport of Motorcycling
  6
- Fuel, Engine Oil and Coolant Recommendations
  14
Controls, Equipment and Adjustments

22
- Location of Parts
  23
- Ignition Switch
  26
- Key
  26
- Instrument Panel
  29
- Left Handlebar
  43
- Right Handlebar
  46
- Fuel Tank Cap
  49
- Gearshift Lever
  50
- Rear Brake Pedal
  51
- Seat Lock and Helmet Holders
  51
- Side Stand
  53
- Suspension Adjustment
  54
- Footrests and Gearshift Lever Position Change
  59
- Break-In and Inspection before Riding
  62
Riding Tips

66
- Starting the Engine
  67
- Starting off
  69
- Using the Transmission
  70
- Riding on Hills
  71
- Stopping and Parking
  72
- Carrying a Passenger
  73
Accessory Use and Motorcycle Loading

74
- Accessory Installation Guidelines
  75
- Accessory Use
  75
- Loading Limit
  76
- Loading Guidelines
  77
- Modification
  77
Inspection and Maintenance

80
- Maintenance Schedule
  81
- Steering Damper Maintenance
  85
- Tools
  85
- Lubrication Points
  86
- Battery
  87
- Air Cleaner
  89
- Spark Plugs
  93
- Engine Oil
  99
- Engine Idle Speed Inspection
  105
- Throttle Cable Play
  105
- Fuel Hose
  106
- Clutch Adjustment
  107
- Engine Coolant
  107
- Drive Chain
  109
- Brakes
  113
- Tires
  118
- Side Stand/Ignition Interlock System
  121
- Front Wheel Removal
  122
- Rear Wheel Removal
  125
- Light Bulb Replacement
  128
- Fuses
  134
- Catalytic Converter
  136
- Troubleshooting
  138

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SUZUKI GSX-R600 Manuals

suzuki GSX-R600 Manual (653 pages)

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Specifications

Special Tools and Equipment

Engine Electrical Devices

Precautions

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

General Description

Repair Instructions