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Suzuki Manuals
Motorcycle
2001 GSX-R600
Service manual
Suzuki 2001 GSX-R600 Service Manual
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Table Of Contents
400
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400
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Foreword
Group Index
How to Use this Manual
Component Parts and Work to be Done
Symbol
Abbreviations May be Used in this Manual
General Information
Warning/Caution/Note
Suzuki GSX-R600K1 (2001-Model) View
Serial Number Location
Fuel, Oil and Engine Coolant Recommendation Fuel (for USA and Canada)
Fuel (for Other Countries)
Engine Oil (for U.S.A. Model)
Engine Oil (for the Other Models)
Engine Coolant
Water for Mixing
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Dimensions and Dry Mass
Transmission
Capacities
Country and Area Codes
Periodic Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Air Cleaner
Spark Plug and Ignition Coil/Plug Cap Removal
Heat Range
Carbon Deposits
Spark Plug Gap
Electrode's Condition
Spark Plug and Ignition Coil/Plug Cap Installation
Valve Clearance
Valve Clearance Adjustment
Tappet Shim Selection Table
Intake Side
Exhaust Side
Engine Oil and Oil Filter
Engine Oil Replacement
Oil Filter Replacement
Fuel Hose
Engine Idle Speed
Throttle Valve Synchronization
Throttle Cable Play
Minor Adjustment
Major Adjustment
Clutch
Cooling System
Engine Coolant Level Check
Engine Coolant Change
Air Bleeding the Cooling Circuit
Radiator Hoses
Drive Chain
Checking
Adjusting
Cleaning and Lubricating
Brake Fluid Level Check
Brake Pads
Front Brake
Rear Brake
Brake Pedal Height
Brake Light Switch
Air Bleeding from Brake Fluid Circuit
Tire Tread Condition
Tire Pressure
Steering
Front Fork
Rear Suspension
Exhaust Pipe Bolt and Nut
Chassis Bolts and Nuts
Compression Pressure Check
Compression Pressure Specification
Compression Test Procedure
Oil Pressure Check
Low Oil Pressure
High Oil Pressure
Oil Pressure Test Procedure
Engine
Engine Components Removable with Engine in Place
Engine Center
Engine Right Side
Engine Left Side
Engine Removal and Reinstallation
Radiator
Exhaust Pipe and Muffler
Electric Parts
Engine Sprocket and Gear Shift Lever
Engine Reinstallation
Engine Disassembly
Starter Motor
Pair Valve
Cylinder Head Cover
Camshafts
Cylinder Head
Oil Pump
Gear Shift System
Starter Idle Gear
Starter Clutch
Cam Chain, Cam Chain Tensioner and Cam Chain Guide
CKP Sensor
Generator Cover
Generator Rotor
Water Pump
Gear Position Switch
Breather Cover
Oil Filter
Oil Cooler
Oil Pan
Oil Pressure Regulator
Oil Pressure Switch
Lower Crank Case
Middle Crankcase
Crankshaft
Piston and Conrod
Engine Components Inspection and Service
Pair Reed Valve
Pair Control Valve
Cam Position Sensor
Camshaft Identification
Cam Wear
Camshaft Journal Wear
Сamshaft Runout
Сam Sprocket
Сam Chain Tension Adjuster
Сam Chain Tensioner
Сylinder Head and Valve
Valve and Valve Spring Disassembly
Cylinder Head Distortion
Valve Stem Runout
Valve Head Radial Runout
Valve Face Wear
Valve Stem Deflection
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width Inspection
Valve Seat Servicing
Initial Seat Cut
Top Narrowing Cut
Bottom Narrowing Cut
Final Seat Cut
Valve Stem End Condition
Valve Spring
Valve and Valve Spring Reassembly
Intake Pipe
Water Bypass Union
Clutch Drive Plates Inspection
Clutch Spring Inspection
Clutch Bearing Inspection
Generator
Gearshift Shaft/Gearshift Arm Disassembly
Gearshift Shaft/Gearshift Arm Inspection
Gearshift Shaft/Gearshift Arm Reassembly
Oil Strainer
Transmission View
Reassembly
Transmission Parts Location
Cylinder Distortion
Cylinder Bore
Piston and Piston Ring
Piston Diameter
Piston to Cylinder Clearance
Piston Pin and Pin Bore
Piston Ring to Groove Clearance
Piston Ring Free End Gap and Piston Ring End Gap
Piston Ring Reassembly
Gearshift Fork and Gearshift Cam
Gearshift Fork to Groove Clearance
Gearshift Fork Groove Width
Gearshift Fork Thickness
Bearing Removal
Installation
Oil Jet
Inspection and Cleaning
Plugs
Crankshaft and Conrod
Crankshaft Runout
Conrod Small End I.D.
Conrod Big End Side Clearance
Conrod-Big End Bearing Inspection
Conrod-Big End Bearing Selection
Bearing Selection Table
Conrod I.D.
Crank Pin O.D.
Bearing Thickness
Crankshaft Journal Bearing
Selection
Crankcase I.D. Specification
Crankshaft Journal O.D. Specification
Bearing Thickness Specification
Crankshaft Thrust Bearing
Crankshaft Thrust Clearance Adjustment
Thrust Bearing Selection Table
Engine Reassembly
Cam Chain Drive Sprocket
Cam Chain Tensioner and Cam Chain Guide
Gearshift System
Clutch Cover
Camshaft
Cam Chain Tension Adjuster
FI System and Intake Air System
Precautions in Servicing
Connector/Coupler
Fuse
Ecm/Various Sensors
Electrical Circuit Inspection Procedure
Open Circuit Check
Continuity Check
Voltage Check
Short Circuit Check (Wire Harness to Ground)
Using the Tester
FI System Technical Features
Injection Time (Injection Volume)
Compensation of Injection Time (Volume)
Injection Stop Control
Fuel Delivery System
Fuel Pump
Fuel Pressure Regulator
Fuel Injector
Fuel Pump Control System
ECM (FI Control Unit)
Injection Timing
Intake Air Pressure Sensor (IAP Sensor)
Throttle Position Sensor (TP Sensor)
Crankshaft Position Sensor (CKP Sensor)
Camshaft Position Sensor (CMP Sensor)
Intake Air Temperature Sensor (IAT Sensor)
Engine Coolant Temperature Sensor (ECT Sensor)
Atmospheric Pressure Sensor (AP Sensor)
Tip over Sensor (to Sensor)
Secondary Throttle Position Sensor (STP Sensor)
Intake Air System
Secondary Throttle Control System
Operation
FI System Parts Location
FI System Diagram
FI System Wiring Diagram
Self-Diagnosis Function
User Mode
Dealer Mode
Setting Procedure
Fail-Safe Function
FI System Trouble Shooting
Self-Diagnostic Procedures
Self-Diagnosis Reset Procedure
Malfunction Code and Defective Condition
"C11" CMP Sensor Circuit Malfunction
"C12" CKP Sensor Circuit Malfunction
"C13" IAP Sensor Circuit Malfunction
Output Voltage
"C14" TP Sensor Circuit Malfunction
"C15" ECT Sensor Circuit Malfunction
"C21" IAT Sensor Circuit Malfunction
"C22" AP Sensor Circuit Malfunction
"C23" to Sensor Circuit Malfunction
"C28" STV Actuator Circuit Malfunction
"C29" STP Sensor Circuit Malfunction
“C30” STC Unit Circuit Malfunction
"C31" Gear Position (GP) Switch Circuit Malfunction
"C32", "C33", "C34" or "C35" Fuel Injector Circuit Malfunction
"C41" FP Relay Circuit Malfunction
"C42" IG Switch Circuit Malfunction
Fuel System
Fuel Tank Lift-Up
Fuel Tank Removal
Fuel Tank Installation
Fuel Pressure Inspection
Fuel Pump Inspection
Fuel Discharge Amount Inspection
Fuel Pump Relay Inspection
Fuel Pump and Fuel Filter Removal
Construction
Fuel Mesh Filter Inspection and Cleaning
Fuel Pump and Fuel Mesh Filter Installation
Throttle Body and STV Actuator Construction
Air Cleaner Box and Throttle Body Removal
Throttle Body
Throttle Body Disassembly
Throttle Body Cleaning
Throttle Body Reassembly
Wire Color
Throttle Body Installation
STP Sensor Adjustment
Throttle Body Clamp Position
Fuel Injector Inspection
Fuel Injector Removal
Fuel Injector Installation
Fast Idle Adjustment
Calibrating each Gauge
Throttle Position Sensor (TPS) Setting
Throttle Cable Adjustment
IAP Sensor Removal/Installation
TP Sensor Removal/Installation
CKP Sensor Inspection
CMP Sensor Removal/Installation
ECT Sensor Inspection
AP Sensor Removal/Installation
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Table of Contents
Troubleshooting
FI System Trouble Shooting
177
Troubleshooting
353
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This manual is also suitable for:
2002 gsx-r600
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