Руководство по ремонту suzuki gsx

Руководство на английском языке по техническому обслуживанию и ремонту мотоциклов Suzuki GS250/GS400/GS450 и GSX250/GSX400/GSX450 1979-1985 годов выпуска.

  • Издательство: Haynes Publishing
  • Год издания: 1986
  • Страниц: 236
  • Формат: PDF
  • Размер: 51,6 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX250F.

  • Издательство: Suzuki Motor Corporation
  • Год издания: 1991
  • Страниц: 229
  • Формат: PDF
  • Размер: 6,9 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX400F.

  • Издательство: Suzuki Motor Corporation
  • Год издания: —
  • Страниц: 292
  • Формат: PDF
  • Размер: 39,9 Mb

Руководство на английском языке по техническому обслуживанию и ремонту мотоциклов Suzuki GSX600F, GSX750 и GSX750F 1998-2002 годов выпуска.

  • Издательство: Haynes Publishing
  • Год издания: 2003
  • Страниц: —
  • Формат: JPG
  • Размер: 64,1 Mb

Руководство на английском языке по техническому обслуживанию и ремонту мотоциклов Suzuki GSX600F Katana, GSX750F Katana, GSX1100F Katana 1988-1996 годов выпуска и GSX-R750, GSX-R1100 1985-1992 годов выпуска.

  • Издательство: Haynes Publishing
  • Год издания: —
  • Страниц: 256
  • Формат: PDF
  • Размер: 37,5 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSF650, GSF650S и GSX650F.

  • Издательство: Suzuki Motor Corporation
  • Год издания: 2007
  • Страниц: 620
  • Формат: PDF
  • Размер: 28,9 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX750E и GSX750ES 1984-1986 годов выпуска.

  • Издательство: Suzuki Motor Corporation
  • Год издания: —
  • Страниц: 309
  • Формат: PDF
  • Размер: 18,9 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GS1150 и GSX1100.

  • Издательство: Suzuki Motor Corporation
  • Год издания: —
  • Страниц: 306
  • Формат: PDF
  • Размер: 42,4 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX1300BK B-King.

  • Издательство: Suzuki Motor Corporation
  • Год издания: 2007
  • Страниц: 686
  • Формат: PDF
  • Размер: 35,6 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX1300R.

  • Издательство: Suzuki Motor Corporation
  • Год издания: —
  • Страниц: 645
  • Формат: PDF
  • Размер: 13,9 Mb

Сборник руководств на английском языке по ремонту мотоциклов Suzuki GSX1300R.

  • Издательство: Suzuki Motor Corporation
  • Год издания: 1999/2000/2001
  • Страниц: 503/31/18
  • Формат: PDF
  • Размер: 107,6 Mb

Руководство на английском языке по ремонту мотоциклов Suzuki GSX1400.

  • Издательство: Suzuki Motor Corporation
  • Год издания: 2001
  • Страниц: 354
  • Формат: PDF
  • Размер: 23,6 Mb

Руководство на английском языке по эксплуатации и техническому обслуживанию мотоциклов Suzuki GSX1400.

  • Издательство: Suzuki Motor Corporation
  • Год издания: —
  • Страниц: 37
  • Формат: PDF
  • Размер: 6,0 Mb

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Suzuki GSX600F Katana

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Для Suzuki GSX600F Katana

  • Руководство по ремонту и обслуживанию (Haynes Service & Repair Manual) для Suzuki GSX600F Katana (1988-1996)
  • Руководство по ремонту и обслуживанию (Haynes Service & Repair Manual) для Suzuki GSX600F Katana (1998-2002)
  • Сервисный мануал (Suzuki Service Manual) на Suzuki GSX600F Katana (1999-2001)

Обзор модели

  • Suzuki GSX600F Katana

Источник — «https://bikeswiki.ru/index.php?title=Suzuki_GSX600F_Katana:_мануалы&oldid=9866»

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  1. Manuals
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  5. GSX-R600

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

suzuki GSX-R600 Manual (653 pages)

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

Table of Contents

  • 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

Advertisement

Suzuki GSX-R600 Service Manual

Suzuki GSX-R600 Service Manual (466 pages)

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

Table of Contents

  • 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

Suzuki GSX-R600 Manual (165 pages)

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

Table of Contents

  • 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

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SUZUKI Categories

Motorcycle

Automobile

Musical Instrument

Offroad Vehicle

Outboard Motor

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