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Intruder VS600GL
Suzuki Intruder VS600GL Manuals
Manuals and User Guides for Suzuki Intruder VS600GL. We have
1
Suzuki Intruder VS600GL manual available for free PDF download: Service Manual
Suzuki Intruder VS600GL Service Manual (278 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 18.73 MB
Table of Contents
Group Index
2
How to Use this Manual
3
Component Parts and Work to be Done
3
Symbols
4
General Information
5
General Precautions
6
Serial Number Location
8
Fuel, Oil and Engine Coolant Recommendation
8
Fuel
8
Engine Oil
8
Anti-Freeze/Engine Coolant
9
Liquid Amount of Water/Engine Coolant
9
Break-In Procedures
10
Cylinder Identification
10
Information Labels
11
Specifications
12
Dimensions and Dry Mass
12
Engine Specifications
12
Transmission Specifications
12
Chassis Specifications
13
Electrical Specifications
13
Capacities
13
Country or Area
14
Periodic Maintenance
15
Periodic Maintenance Shedule
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Battery
18
Air Cleaner
20
Front Side Air Cleaner
20
Rear Side Air Cleaner
20
Valve Clearance
21
Spark Plug
23
Engine Oil and Oil Filter
24
Fuel Hose
25
Fuel Valve Strainer
25
Carburetor
25
Throttle Cable Play
25
Cooling System
26
Final Gear Oil
26
Clutch
27
Clutch Fluid Level
27
Bleeding Air from the Clutch Fluid Circuit
27
Brake
28
Front Brake
28
Brake Fluid Level
28
Brake Pad
28
Air Bleeding the Brake Fluid Circuit
29
Rear Brake
29
Tire
30
Tire Pressure
30
Brake Light Switch
30
Brake Shoe Wear
30
Steering
31
Front Fork
31
Rear Suspension
31
Exhaust Pipe Bolts
31
Chassis Bolts and Nuts
32
Compression Pressure Check
34
Compression Pressure Specification
34
Compression Test Procedure
34
Oil Pressure Check
35
Low Oil Pressure
35
High Oil Pressure
35
Engine
36
Engine Components Removable with the Engine in Place
37
Engine Removal
38
Engine Reinstallation
44
Engine Disassembly
46
Transmission Disassembly
57
Transmision: Lubrication Related Parts
58
Crankcase Bearing and Oil Seal
59
Cooling System Related Parts
60
Engine Components Inspection and Servicing
61
Cylinder Head Cover Disassembly
61
Cylinder Head Cover Distortion
61
Rocker Arm I.D.
62
Camshaft
62
Camshaft Cam Wear
62
Camshaft Journal Wear
63
Cylinder Head Cover Bolts Tightening Torque
63
Camshaft Runout
64
Cam Chain Tensioner
64
Cam Chain Guide
64
Valve and Valve Spring Disassembly
65
Cylinder Head Distortion
65
Valve Face Wear
66
Valve Stem Runout
66
Valve Head Radial Runout
66
Valve Stem Deflection
66
Valve Stem Wear
67
Valve Guide Servicing
67
Valve Seat Width
68
Valve Seat Servicing
69
Valve Stem End Condition
70
Valve Spring
70
Valve and Valve Spring Reassembly
71
Cylinder Distortion
71
Valve Spring Tension Table
71
Cylinder Bore
72
Piston Diameter
72
Piston to Cylinder Clearance
72
Piston Ring Free End Gap and End Gap
73
Piston Ring to Groove Clearance Table
73
Piston Ring Groove Width Table
73
Piston Pin and Pin Bore
74
Oversize Oil Ring
74
Oversize Side Rail
74
Conrod Small End I.D.
75
Conrod Big End Thrust Clearance
75
Conrod-Crank Pin Bearing Selection
75
Crank Pin Bearing Oil Clearance
76
Bearing Selection Table
76
Conrod I.D. Specification Table
77
Crank Pin O.D. Specification Table
77
Bearing Thickness Table
77
Conrod-Crank Pin Bearing Assembly
78
Crankcase-Crankshaft Bearing Selection
78
Crankshaft Thrust Clearance
79
Clutch Drive Plate and Driven Plate
80
Clutch Spring Free Length
81
Clutch Bearing
81
Generator and Signal Generator Servicing
82
Starter Clutch Servicing
82
Oil Pump
83
Transmission
83
Transmission Gears and Related Parts
83
Gear-Shifting Fork Clearance
84
Countershaft and Driveshaft
84
Top Drive Gear Bushing
85
Low and 3Rd Driven Gear Bushings
85
3Rd Driven Gear Lock Washers
85
Engine Reassembly
86
Secondary Bevel Gear Case Bolt
90
Secondary Driven Bevel Gear Housing Bolt
90
Secondary Driven Bevel Gear Shaft Nut
90
Geafshift Arm Stopper
91
Oil Pump Bolt
91
Cam Chain Guide Set Bolt
92
Primary Drive Gear Bolt
92
Oil Filter Wrench
93
Snap Ring Pliers
93
Clutch Sleeve Hub Nut
94
Clutch Spring Mounting Bolt
95
Cylinder Head Bolts and Nuts
98
Camshaft Timing
100
(Rear) Engine
100
(Front) Engine
101
Cam Shaft Timing
102
Location of Cylinder Head Bolt
105
Location of Cylinder Head Cover Bolt
105
Valve Inspection Cap and Cam Timing Inspection Cap
106
Intake Pipe
106
Shaft Drive
107
Shaft Drive Diagram
108
Secondary Bevel Gears Construction
109
Secondary Bevel Gear Removal and Disassembly
110
Secondary Drive Bevel Gear Inspection
110
Secondary Drive Bevel Gear Reassembly
111
Secondary Gears Shim Adjustment
111
Backlash
111
Tooth Contact
113
Reassembly Information
114
Final Bevel Gears Construction
115
Final Gear Case Breather Circuit
116
Air and Gear Oil Flow in Final Gear Case Breather Circuit
116
Air Passage
116
Oil Passage
116
Final Bevel Gear Removal and Disassembly
117
Final Gear Case
117
Propeller Shaft
117
Driven Bevel Gear
117
Drive Bevel Gear
118
Final Bevel Gears Inspection
120
Final Bevel Gears Reassembly
120
Final Gear Case and Bearing Case
121
Final Gear Shim Adjustment
123
Final Gear Bearing Case Shim Clearance
123
Backlash too Large
124
Backlash too Small
124
Tooth Contact
125
Final Assembly and Remounting
126
Shaft Drive Reassembly Information
128
Fuel and Lubrication System
129
Fuel System Overview
130
Fuel Pump Description
131
Fuel Pump Removal
132
Fuel Pump Inspection
132
Fuel Tank and Fuel Valve
133
Fuel Valve Mechanism
133
Fuel Tank Removal
133
Fuel Valve Removal
133
Carburetor Consruction
134
(Rear) Carburetor Exploded View
135
Carburetor Specifications
136
I.D. NO. Location
138
Diaphragm and Piston Operation
138
Slow System
139
Transient Enrichment System
139
Main System
140
Starter System
141
Float System
141
Carburetor Removal
142
Carburetor Disassembly
145
Carburetor Inspection and Adjustment
147
Needle Valve Inspection
147
Carburetor Reassembly and Remounting
148
Balance of Carburetors
149
In Case of Changing the Synchronizing Cable
149
In Case of Changing the Throttle Cable
150
Lubrication System
151
Oil Sump Filter
151
In Case of Changing the Carburetors
151
Engine Lubrication System Chart
152
Engine Lubrication System View
153
Cooling System - Contents
154
Cooling System Overview
155
Cooling System Construction
156
Cooling System Exploded View
157
Engine Coolant
158
Cooling System Removal and Disassembly
159
Radiator and Water Hoses
159
Cooling Fan
159
Cooling Fan Thermo-Switch
160
Engine Coolant Temperature Gauge
160
Water Pump
160
Thermostat
162
Radiator Inspection
163
Radiator Removal
163
Radiator Installation
164
Cooling Fan Inspection
164
Cooling Fan Installation
164
Engine Coolant Temperature Gauge Inspection
165
Temperature Gauge Specification
165
Engine Coolant Temperature Gauge Reassembly
165
Cooling Fan Thermo-Switch Inspection
166
Thermo-Switch Specification
166
Cooling Fan Thermo-Switch Reassembly
166
Water Pump Removal and Disassembly
167
Water Pump Inspection
167
Water Pump Bearing
167
Water Pump Reassembly
167
Thermostat Inspection
169
Thermostat Valve Opening Temperature
169
Thermostat Reassembly
169
Chassis
170
Chassis Exterior Parts
171
Frame Cover Removal
171
Seat Removal
171
Rear Cushion Removal
171
Fuel Tank Mounting Bracket Removal
172
Frame Head Cover Removal
172
Chassis Exterior Parts Remounting
172
Front Wheel Exploded View
173
Front Wheel Removal
173
Speedometer Gearbox Inspection
174
Front Wheel Inspection
174
Wheel Bearings Inspection
174
Brake Disc
176
Speedometer Gearbox
176
Front Axle
177
Front Brake Exloded View
178
Brake Pad Replacement
179
Brake Fluid Replacement
179
Caliper Removal and Disassembly
180
Caliper Inspection
181
Caliper Reassembly and Remounting
181
Brake Disc Inspection
182
Master Cylinder Removal and Disassembly
183
Master Cylinder Inspection
184
Master Cylinder Reassembly and Remounting
184
Front Fork Exploded View
186
Front Fork Removal and Disassembly
186
Front Fork Inspection
189
Front Fork Reassembly and Remounting
189
Inner Tube Metal
189
Damper Rod
189
Outer Tube Metal, Oil Seal and Dust Seal
190
Fork Oil
190
Fork Spring
191
Front Fork Remounting
191
Steering Exploded View
193
Steering Removal and Disassembly
193
Steering Inspection and Disassembly
195
Steering Reassembly and Remounting
195
Outer Races
195
Handlebar Holder
196
Steering Stem Head Unit
196
Steering Tension Adjustment
197
Handlebars
197
Front Fork Lower Clamp Bolt
197
Rear Wheel and Brake Exploded View
198
Rear Wheel and Brake Removal
198
Rear Wheel and Brake Disassembly
199
Rear Wheel and Brake Inspection
201
Brake Shoe
201
Brake Panel
201
Brake Drum
202
Wheel Damper
202
Rear Wheel and Brake Reassembly and Remounting
202
Wheel Bearings
202
Rear Brake Pedal Removal and Reassembly
204
Rear Brake Pedal Inspection
205
Rear Brake Pedal Remounting and Reassembly
205
Rear Suspension and Swingarm Exploded View
206
Rear Suspension and Swingarm Removal
206
Rear Suspension and Swingarm Inspection and Disassembly
208
Swingarm Pivot Bearings
208
Shock Absorber
208
Swingarm Pivot Shaft
208
Rear Suspension and Swingarm Reassembly and Remounting
209
Swingarm Bearing
209
Rear Swingarm Pivot Nut
209
Final Bevel Gear Case
209
Final Inspection and Adjustment
210
Rear Shock Absorber
210
Clutch Master Cylinder Exploded View
211
Clutch Master Cylinder Disassembly and Reassembly
211
Electrical System
212
Cautions in Servicing the Electrical System
213
Connector
213
Coupler, Clamp, Fuse
213
Semi-Conductor Equipped Part
213
Connecting Battery
214
Wiring Procedure
214
Using Pocket Tester
214
Location of Electrical Components
215
Charging System Description
216
Function of Regulator
216
Charging System Troubleshooting
218
Battery Leak Current Inspection
219
Charging Output Inspection
219
Generator Coil Continuity Inspection
220
Generator No-Load Performance Inspection
220
Regulator/Rectifier Inspection
220
Starter System and Side-Stand/Ignition Interlock System
221
Starter System Description
221
Starter System Troubleshooting
223
Starter Motor Removal and Disassembly
224
Starter Motor Inspection
225
Carbon Brush and Commutator Inspection
225
Armature Coil Inspection
225
Starter Motor Reassembly
225
Starter Relay Inspection
226
Side-Stand/Ignition Interlock System Part Inspection
227
Diode
227
Neutral Switch
227
Side-Stand Switch
227
Side-Stand/Ignition Interlock Relay
228
Ignition System Description
229
Ignition System Troubleshooting
230
Ignition Coil Inspection (Checking with Electro Tester)
231
Ignition Coil Inspection (Checking with Pocket Tester)
231
Spark Plugs Inspection
232
Electrode's Condition
232
Heat Range
232
Ignition Unit Checking with Digital Ignitor Checker
233
Speedometer and Instrument Panel Removal and Disassembly
235
Speedometer and Instrument Panel Inspection
235
Engine Coolant Temperature Indicator Inspection
237
Lamps
238
Headlight
238
Tail/Brake Light
238
Turns Signal Light
239
Starter Relay
239
Side-Stand Relay
239
Turn Signal Relay
239
Switches
240
Battery Specifications
241
Battery Charging
241
Filling Electrolyte
241
Battery Servicing
241
Recharging Operation Based on S.G. Reading
242
Battery Service Life
243
Servicing Information
244
Troubleshooting - Engine
245
Troubleshooting - Shaft Drive
248
Troubleshooting - Carburetor
248
Troubleshooting - Radiator
249
Troubleshooting - Chassis
249
Troubleshooting - Brakes
250
Troubleshooting - Electrical
251
Troubleshooting - Battery
252
Wiring Diagram
253
Wire Harness Routing Diagram
254
Cable Routing Diagram
256
Fuel System Hose Routing Diagram
258
Cooling System Hose Routing Diagram
260
Front Brake House Routing Diagram
261
Clutch Hose Routing Diagram
262
Special Tools
263
Tightening Torque - Engine
266
Tightening Torque - Engine Cooling
267
Tightening Torque - Shaft Drive
267
Tightening Torque - Chassis
267
Tightening Torque Chart for Other Bolts and Nuts Listed Previously
268
Service Data - Valve + Guide
269
Service Data - Camshaft + Cylinder Head
269
Service Data - Cylinder + Piston + Piston Ring
270
Service Data - Conrod + Crankshaft
271
Service Data - Oil Pump
271
Service Data - Clutch
272
Service Data - Transmission
272
Service Data - Shaft Drive
272
Service Data - Carburetor (E-02, 04, 34)
273
Service Data - Carburetor (E-22)
273
Service Data - Carburetor (E-22 (VS600GLUS))
274
Service Data - Carburetor (E-18)
274
Service Data - Electrical
275
Service Data - Wattage
275
Service Data - Brake + Wheel
276
Service Data - Suspension
276
Service Data - Tire Pressure
277
Service Data - Fuel + Oil + Coolant
277
Service Data - Thermostat + Radiator + Fan
277
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