Мануал для suzuki gsx r600

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

    • Engine Symptom Diagnosis

      77

    • Self-Diagnostic Procedures

      81

    • Use of SDS Diagnosis Reset Procedures

      83

    • Show Data When Trouble (Displaying Data at the Time of DTC)

      84

    • SDS Check

      85

    • DTC Table

      89

    • Fail-Safe Function Table

      91

    • FI System Troubleshooting

      92

    • Malfunction Code and Defective Condition Table

      94

      • DTC «C11» (P0340): CMP Sensor Circuit Malfunction

        98

      • DTC «C12» (P0335): CKP Sensor Circuit Malfunction

        101

      • DTC «C13» (P0105-H/L): IAP Sensor Circuit Malfunction

        104

      • DTC «C14» (P0120-H/L): TP Sensor Circuit Malfunction

        113

      • DTC «C15» (P0115-H/L): ECT Sensor Circuit Malfunction

        120

      • DTC «C21» (P0110-H/L): IAT Sensor Circuit Malfunction

        125

      • DTC «C22» (P1450-H/L): AP Sensor Circuit Malfunction

        130

      • DTC «C23» (P1651-H/L): to Sensor Circuit Malfunction

        139

    • DTC «C24» (P0351), «C25» (P0352), «C26» (P0353) or «C27» (P0354): Ignition System Malfunction

      146

    • DTC «C28» (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction

      146

    • DTC «C29» (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction

      150

    • DTC «C31» (P0705): GP Switch Circuit Malfunction

      157

    • DTC «C32» (P0201), «C33» (P0202), «C34» (P0203) or «C35» (P0204): Primary Fuel Injector Circuit Malfunction

      159

    • DTC «C36» (P1764), «C37» (P1765), «C38» (P1766) or «C39» (P1767): Secondary Fuel Injector Circuit Malfunction

      162

    • DTC «C40» (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction

      165

    • DTC «C41» (P0230-H/L): FP Relay Circuit Malfunction

      169

    • DTC «C41» (P2505): ECM Power Input Signal Malfunction

      172

    • DTC «C42» (P1650): IG Switch Circuit Malfunction

      174

    • DTC «C44» (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction

      174

    • DTC «C46» (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction

      180

    • DTC «C49» (P1656): PAIR Control Solenoid Valve Circuit Malfunction

      194

    • DTC «C60» (P0480): Cooling Fan Relay Circuit Malfunction

      197

    • DTC «C62» (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 Only)

      200

    • DTC «C91» (P0500): Vehicle Speed Sensor Circuit Malfunction

      203

    • DTC «C93» (P1769): Steering Damper Solenoid Valve Circuit Malfunction

      206

  • 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

    • Fuel Injection System Description

      213

    • Crankcase Emission Control System Description

      214

    • Exhaust Emission Control System Description

      215

    • Noise Emission Control System Description

      216

    • Evaporative Emission Control System Diagram (Only for

      216

  • Schematic and Routing Diagram

    217

    • PAIR System Hose Routing Diagram

      217

    • EVAP Canister Hose Routing Diagram

      218

  • Repair Instructions

    219

    • Heated Oxygen Sensor (HO2S) Removal and Installation

      219

    • Heated Oxygen Sensor (HO2S) Inspection

      219

    • PAIR Reed Valve Removal and Installation

      219

    • PAIR Control Solenoid Valve Removal and Installation

      221

    • PAIR System Inspection

      221

    • Crankcase Breather (PCV) Hose Inspection

      222

    • Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation

      223

    • Crankcase Breather (PCV) Cover Inspection

      224

    • Crankcase Breather (PCV) Reed Valve Inspection

      224

    • Evaporative Emission Control System Removal and Installation (Only for

      224

    • Evaporative Emission Control System

      224

    • Inspection (Only for

      224

  • 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

    • Engine Oil and Filter Replacement

      332

    • Engine Oil Level Inspection

      332

    • Oil Pan / Oil Strainer / Oil Pressure Regulator

      332

      • Removal and Installation

        332

    • Oil Pressure Regulator / Oil Strainer Inspection

      333

    • Oil Cooler / Oil Cooler Hose Inspection

      334

    • Oil Cooler Removal and Installation

      334

    • Oil Pressure Switch Removal and Installation

      335

    • Oil Pressure Switch Inspection

      335

    • Oil Jet / Oil Gallery Jet Removal and Installation

      335

    • Oil Jet / Oil Gallery Jet Inspection

      337

    • Oil Pump Removal and Installation

      338

    • Oil Pump Inspection

      339

    • Oil Pump Drive Gear Removal and Installation

      339

  • 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

    • Ignition Coil / Plug Cap and Spark Plug Removal and Installation

      381

    • Spark Plug Inspection and Cleaning

      382

    • Ignition Coil / Plug Cap Inspection

      382

    • CKP Sensor Inspection

      384

    • CKP Sensor Removal and Installation

      385

    • Engine Stop Switch Inspection

      385

    • Ignition Switch Inspection

      385

    • Ignition Switch Removal and Installation

      386

    • Drive Mode Selector Inspection

      387

  • 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

    • Starting System Symptom Diagnosis

      390

    • Starter Motor will Not Run

      391

    • Starter Motor Runs but Does Not Crank the Engine

      391

  • Repair Instructions

    392

    • Starter Motor Components

      392

    • Starter Motor Removal and Installation

      393

    • Starter Motor Disassembly and Assembly

      393

    • Starter Motor Inspection

      394

    • Starter Relay Removal and Installation

      395

    • Starter Relay Inspection

      396

    • Turn Signal / Side-Stand Relay Removal and Installation

      396

    • Side-Stand / Ignition Interlock System Parts Inspection

      397

    • Starter Clutch Removal and Installation

      399

    • Starter Clutch Inspection

      401

    • Starter Button Inspection

      402

  • 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

    • Rear Suspension Components

      451

    • Rear Suspension Assembly Construction

      452

    • Rear Shock Absorber Removal and Installation

      453

    • Rear Suspension Inspection

      454

    • Rear Shock Absorber Inspection

      454

    • Rear Suspension Adjustment

      454

    • Rear Shock Absorber Disposal

      455

    • Cushion Lever Removal and Installation

      456

    • Cushion Lever Inspection

      456

    • Cushion Lever Bearing Removal and Installation

      457

    • Cushion Rod Removal and Installation

      458

    • Cushion Rod Inspection

      458

    • Cushion Rod Bearing Removal and Installation

      459

    • Swingarm Removal and Installation

      460

    • Swingarm Related Parts Inspection

      462

    • Swingarm Bearing Removal and Installation

      463

  • 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

    • Front Wheel Components

      468

    • Front Wheel Assembly Construction

      469

    • Front Wheel Assembly Removal and Installation

      470

    • Front Wheel Related Parts Inspection

      472

    • Front Wheel Dust Seal / Bearing Removal and Installation

      473

    • Rear Wheel Components

      475

    • Rear Wheel Assembly Construction

      476

    • Rear Wheel Assembly Removal and Installation

      477

    • Rear Wheel Related Parts Inspection

      477

    • Rear Wheel Dust Seal / Bearing Removal and Installation

      479

    • Tire Removal and Installation

      481

    • Wheel / Tire / Air Valve Inspection and Cleaning

      482

    • Air Valve Removal and Installation

      483

    • Wheel Balance Check and Adjustment

      484

  • 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 Related Components

      489

    • Engine Sprocket Removal and Installation

      490

    • Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation

      491

    • Drive Chain Related Parts Inspection

      492

    • Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation

      493

    • Drive Chain Replacement

      495

  • 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

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

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

• Table of Contents

  4

  • The Sport of Motorcycling

    6

    • Most Accidents Can be Avoided

      7

    • If You Don’t Have a Helmet, Buy a Helmet and Wear It Every Time You Ride

      7

    • If a Collision Is Imminent, Do Something

      8

    • Special Situations Require Special Care

      9

    • Know Your Limits

      9

    • Be Extra Safety-Conscious on Bad Weather Days

      10

    • Practice Away from Traffic

      10

    • Inspection before Riding

      10

    • Accessories and Loading

      10

    • Carrying a Passenger

      11

    • Motorcycle Safety Foundation’s «Riding Tips and Practice Guide» Handbook (for Owners in Usa)

      11

    • Be Street Smart

      11

    • Labels

      11

    • Conclusion

      12

  • 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