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2002 GSX-R600
Suzuki 2002 GSX-R600 Motorcycle Manuals
Manuals and User Guides for Suzuki 2002 GSX-R600 Motorcycle. We have
1
Suzuki 2002 GSX-R600 Motorcycle manual available for free PDF download: Service Manual
Suzuki 2002 GSX-R600 Service Manual (400 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 52.9 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 May be Used in this Manual
5
General Information
8
Warning/Caution/Note
9
Suzuki GSX-R600K1 (2001-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 U.S.A. Model)
12
Engine Oil (for the Other Models)
12
Engine Coolant
13
Water for Mixing
13
Break-In Procedures
13
Cylinder Identification
13
Information Labels
14
Specifications
15
Dimensions and Dry Mass
15
Transmission
15
Capacities
16
Country and Area Codes
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
23
Carbon Deposits
23
Spark Plug Gap
23
Electrode's Condition
23
Spark Plug and Ignition Coil/Plug Cap Installation
24
Valve Clearance
25
Valve Clearance Adjustment
27
Tappet Shim Selection Table
28
Intake Side
28
Exhaust Side
29
Engine Oil and Oil Filter
30
Engine Oil Replacement
30
Oil Filter Replacement
31
Fuel Hose
32
Engine Idle Speed
32
Throttle Valve Synchronization
32
Throttle Cable Play
33
Minor Adjustment
33
Major Adjustment
34
Clutch
34
Cooling System
35
Engine Coolant Level Check
35
Engine Coolant Change
35
Air Bleeding the Cooling Circuit
36
Radiator Hoses
36
Drive Chain
37
Checking
37
Adjusting
38
Cleaning and Lubricating
38
Brake Fluid Level Check
39
Brake Pads
39
Front Brake
39
Rear Brake
40
Brake Pedal Height
40
Brake Light Switch
40
Air Bleeding from Brake Fluid Circuit
41
Tire Tread Condition
42
Tire Pressure
43
Steering
43
Front Fork
44
Rear Suspension
44
Exhaust Pipe Bolt and Nut
44
Chassis Bolts and Nuts
45
Compression Pressure Check
47
Compression Pressure Specification
47
Compression Test Procedure
47
Oil Pressure Check
48
Low Oil Pressure
48
High Oil Pressure
48
Oil Pressure Test Procedure
48
Engine
50
Engine Components Removable with Engine in Place
51
Engine Center
51
Engine Right Side
51
Engine Left Side
51
Engine Removal and Reinstallation
52
Radiator
53
Exhaust Pipe and Muffler
54
Electric Parts
55
Engine Sprocket and Gear Shift Lever
56
Engine Reinstallation
60
Engine Disassembly
64
Starter Motor
64
Pair Valve
64
Cylinder Head Cover
64
Camshafts
65
Cylinder Head
66
Oil Pump
69
Gear Shift System
69
Starter Idle Gear
70
Starter Clutch
71
Cam Chain, Cam Chain Tensioner and Cam Chain Guide
71
CKP Sensor
71
Generator Cover
72
Generator Rotor
72
Water Pump
72
Gear Position Switch
73
Breather Cover
73
Oil Filter
73
Oil Cooler
73
Oil Pan
74
Oil Pressure Regulator
74
Oil Pressure Switch
74
Lower Crank Case
74
Middle Crankcase
75
Crankshaft
75
Piston and Conrod
76
Engine Components Inspection and Service
77
Pair Reed Valve
77
Pair Control Valve
77
Cam Position Sensor
78
Camshaft Identification
78
Cam Wear
78
Camshaft Journal Wear
79
Сamshaft Runout
80
Сam Sprocket
80
Сam Chain Tension Adjuster
80
Сam Chain Tensioner
80
Сylinder Head and Valve
81
Valve and Valve Spring Disassembly
81
Cylinder Head Distortion
82
Valve Stem Runout
82
Valve Head Radial Runout
82
Valve Face Wear
82
Valve Stem Deflection
83
Valve Stem Wear
83
Valve Guide Servicing
84
Valve Seat Width Inspection
85
Valve Seat Servicing
85
Initial Seat Cut
86
Top Narrowing Cut
86
Bottom Narrowing Cut
86
Final Seat Cut
87
Valve Stem End Condition
88
Valve Spring
88
Valve and Valve Spring Reassembly
89
Intake Pipe
90
Water Bypass Union
90
Clutch Drive Plates Inspection
91
Clutch Spring Inspection
91
Clutch Bearing Inspection
91
Generator
92
Gearshift Shaft/Gearshift Arm Disassembly
93
Gearshift Shaft/Gearshift Arm Inspection
93
Gearshift Shaft/Gearshift Arm Reassembly
93
Oil Strainer
94
Transmission View
95
Reassembly
96
Transmission Parts Location
97
Cylinder Distortion
98
Cylinder Bore
98
Piston and Piston Ring
99
Piston Diameter
99
Piston to Cylinder Clearance
99
Piston Pin and Pin Bore
99
Piston Ring to Groove Clearance
100
Piston Ring Free End Gap and Piston Ring End Gap
100
Piston Ring Reassembly
101
Gearshift Fork and Gearshift Cam
102
Gearshift Fork to Groove Clearance
102
Gearshift Fork Groove Width
102
Gearshift Fork Thickness
102
Bearing Removal
103
Installation
104
Oil Jet
106
Inspection and Cleaning
106
Plugs
107
Crankshaft and Conrod
108
Crankshaft Runout
108
Conrod Small End I.D.
108
Conrod Big End Side Clearance
108
Conrod-Big End Bearing Inspection
109
Conrod-Big End Bearing Selection
109
Bearing Selection Table
110
Conrod I.D.
110
Crank Pin O.D.
110
Bearing Thickness
110
Crankshaft Journal Bearing
111
Selection
111
Crankcase I.D. Specification
112
Crankshaft Journal O.D. Specification
112
Bearing Thickness Specification
112
Crankshaft Thrust Bearing
113
Crankshaft Thrust Clearance Adjustment
113
Thrust Bearing Selection Table
114
Engine Reassembly
115
Cam Chain Drive Sprocket
129
Cam Chain Tensioner and Cam Chain Guide
129
Gearshift System
132
Clutch Cover
137
Camshaft
140
Cam Chain Tension Adjuster
143
FI System and Intake Air System
147
Precautions in Servicing
149
Connector/Coupler
149
Fuse
150
Ecm/Various Sensors
150
Electrical Circuit Inspection Procedure
151
Open Circuit Check
151
Continuity Check
152
Voltage Check
153
Short Circuit Check (Wire Harness to Ground)
153
Using the Tester
154
FI System Technical Features
155
Injection Time (Injection Volume)
155
Compensation of Injection Time (Volume)
156
Injection Stop Control
156
Fuel Delivery System
157
Fuel Pump
158
Fuel Pressure Regulator
159
Fuel Injector
159
Fuel Pump Control System
160
ECM (FI Control Unit)
161
Injection Timing
162
Intake Air Pressure Sensor (IAP Sensor)
163
Throttle Position Sensor (TP Sensor)
163
Crankshaft Position Sensor (CKP Sensor)
164
Camshaft Position Sensor (CMP Sensor)
164
Intake Air Temperature Sensor (IAT Sensor)
164
Engine Coolant Temperature Sensor (ECT Sensor)
165
Atmospheric Pressure Sensor (AP Sensor)
165
Tip over Sensor (to Sensor)
166
Secondary Throttle Position Sensor (STP Sensor)
166
Intake Air System
167
Secondary Throttle Control System
167
Operation
168
FI System Parts Location
169
FI System Diagram
171
FI System Wiring Diagram
172
Self-Diagnosis Function
173
User Mode
173
Dealer Mode
174
Setting Procedure
175
Fail-Safe Function
176
FI System Trouble Shooting
177
Self-Diagnostic Procedures
178
Self-Diagnosis Reset Procedure
178
Malfunction Code and Defective Condition
179
"C11" CMP Sensor Circuit Malfunction
181
"C12" CKP Sensor Circuit Malfunction
182
"C13" IAP Sensor Circuit Malfunction
183
Output Voltage
184
"C14" TP Sensor Circuit Malfunction
185
"C15" ECT Sensor Circuit Malfunction
187
"C21" IAT Sensor Circuit Malfunction
188
"C22" AP Sensor Circuit Malfunction
189
"C23" to Sensor Circuit Malfunction
191
"C28" STV Actuator Circuit Malfunction
192
"C29" STP Sensor Circuit Malfunction
193
“C30” STC Unit Circuit Malfunction
195
"C31" Gear Position (GP) Switch Circuit Malfunction
196
"C32", "C33", "C34" or "C35" Fuel Injector Circuit Malfunction
197
"C41" FP Relay Circuit Malfunction
198
"C42" IG Switch Circuit Malfunction
198
Fuel System
199
Fuel Tank Lift-Up
199
Fuel Tank Removal
199
Fuel Tank Installation
199
Fuel Pressure Inspection
200
Fuel Pump Inspection
201
Fuel Discharge Amount Inspection
201
Fuel Pump Relay Inspection
203
Fuel Pump and Fuel Filter Removal
203
Construction
203
Fuel Mesh Filter Inspection and Cleaning
205
Fuel Pump and Fuel Mesh Filter Installation
205
Throttle Body and STV Actuator Construction
208
Air Cleaner Box and Throttle Body Removal
209
Throttle Body
210
Throttle Body Disassembly
211
Throttle Body Cleaning
213
Throttle Body Reassembly
214
Wire Color
215
Throttle Body Installation
217
STP Sensor Adjustment
218
Throttle Body Clamp Position
218
Fuel Injector Inspection
219
Fuel Injector Removal
219
Fuel Injector Installation
219
Fast Idle Adjustment
219
Calibrating each Gauge
220
Throttle Position Sensor (TPS) Setting
223
Throttle Cable Adjustment
223
IAP Sensor Removal/Installation
224
TP Sensor Removal/Installation
224
CKP Sensor Inspection
224
CMP Sensor Removal/Installation
224
ECT Sensor Inspection
225
AP Sensor Removal/Installation
225
TO Sensor Removal/Installation
225
STP Sensor Removal/Installation
225
Cooling and Lubrication System
226
Cooling Circuit Inspection
228
Radiator and Water Hoses
229
Radiator Removal
229
Radiator Cap Inspection
229
Radiator Inspection and Cleaning
229
Radiator Remounting
230
Water Hose Inspection
230
Cooling Fan
231
Cooling Fan Thermo-Switch
231
Engine Coolant Temperature Sensor
233
Thermostat
234
Mechanical Seal
239
Oil Seal
239
Bushing
239
Seal Washer
239
Engine Lubrication System Chart
244
Engine Lubrication System
245
Chassis
247
Exterior Parts
249
Fastener Removal and Reinstallation
249
Screen
249
Body Cowling Cover
250
Right and Left under Cowlings
250
Body Cowling
251
Right and Left Air Intake Pipes
252
Cowling Brace
252
Front Seat
253
Rear Seat and Seat Tail Cover
253
Frame Cover
253
Front Wheel Construction
254
Axle Shaft
256
Wheel Bearing
256
Reassembly and Remounting
257
Brake Disc
258
Spacer Nut
259
Brake Caliper
259
Front Axle
259
Front Fork Construction
260
Damper Rod Disassembly
264
Inner and Outer Tubes
264
Fork Spring
264
Damper Rod
264
Compression Damping Force Adjuster
265
Tube Metals and Seals
265
Damper Rod Bolt
266
Fork Oil
267
Front Fork Cap Bolt
268
Suspension Setting
270
Spring Pre-Load Adjustment
270
Damping Force Adjustment
270
Standard Front Suspension Setting
270
Steering Damper Construction
271
Steering Construction
272
Outer Race
274
Bearing
275
Stem Nut
275
Front Fork and Steering Stem Upper Bracket
276
Steering Tension Adjustment
276
Handlebars Construction
277
Right Handlebar
277
Left Handlebar
277
Rear Wheel Construction
280
Rear Axle
282
Wheel Damper
282
Sprocket
282
Bearings
283
Dust Seals
286
Rear Shock Absorber Construction
288
Rear Shock Absorber Scrapping Procedure
290
Rear Shock Absorber Gas Release
290
Height Adjuster
290
Standard Suspension Setting
291
Rear Suspension Construction
292
Spacer
295
Swingarm Bearing
295
Cushion Lever Bearing
296
Cushion Lever and Cushion Lever Rods
296
Swingarm Pivot Shaft
296
Chain Buffer
296
Swingarm Pivot Thrust Clearance Adjustment
299
Shock Absorber and Cushion Lever Mounting Nut
300
Torque Link
300
Final Inspection and Adjustment
300
Front Brake Construction
301
Brake Pad Replacement
302
Brake Fluid Replacement
302
Caliper Removal and Disassembly
303
Caliper Inspection
304
Caliper Reassembly and Remounting
304
Piston Seal
304
O-Ring
304
Brake Disc Inspection
305
Master Cylinder Removal and Disassembly
306
Master Cylinder Inspection
307
Master Cylinder Reassembly and Remounting
307
Rear Brake Construction
309
Cylinder, Piston and Cup Set
314
Tire and Wheel
315
Tire Removal
315
Wheel Inspection
315
Tire Inspection
315
Valve Inspection
316
Valve Installation
316
Tire Installation
316
Balancer Weight
317
Electrical System
318
Cautions in Servicing
319
Connector
319
Coupler
319
Clamp
319
Connecting the Battery
320
Using the Multi Circuit Tester
320
Location of Electrical Components
321
Charging System
323
Battery Current Leakage
324
Regulated Voltage
325
Generator Coil Resistance
325
Generator No-Load Performance
325
Regulator/Rectifier
326
Starter System and Side-Stand/Ignition Interlock System
327
Starter Motor Removal and Disassembly
328
Starter Motor Inspection
329
Commutator
329
Armature Coil Inspection
329
Starter Motor Reassembly
329
Starter Relay Inspection
330
Side Stand/Ignition Interlock System Parts Inspection
331
Side-Stand Switch
331
Turn Signal/Side-Stand Relay
332
Side-Stand Relay Inspection
333
Diode Inspection
333
Ignition System
334
Ignition Coil Primary Peak Voltage
336
Ignition Coil/Plug Cap Resistance
337
CKP Sensor Peak Voltage
338
CKP Sensor Resistance
339
Secondary Throttle Control Unit
339
Combination Meter
340
Description
340
Led (Light Emitting Diode)
342
Stepping Motor
342
Engine Coolant Temperature Meter and Indicator
343
Fuel Level Indicator Switch Inspection
344
Fuel Level Indicator Light Inspection
344
Fuel Level Resister Inspection
344
Speedometer Sensor
345
Oil Pressure Indicator
345
Lamps
346
Headlight, Brake Light/Taillight and Turn Signal Light
346
Headlight Beam Adjustment
346
Ignition Switch Removal
347
Battery Specifications
349
Initial Charging
349
Filling Electrolyte
349
Servicing
350
Recharging Operation
351
Servicing Information
352
Troubleshooting
353
FI System Malfunction Code and Defective Condition
353
Radiator (Cooling System)
360
Brakes
362
Electrical
363
Battery
364
Wiring Harness, Cable and Hose Routing
365
Cable Routing
368
Fuel Tank Drain Hose Routing
369
Cooling System Hose Routing
370
Front Brake Hose Routing
371
Rear Brake Hose Routing
372
Pair (Air Supply) System Hose Routing
373
Fuel Tank Set-Up
374
Cowling Set-Up
375
Frame Cover Set-Up
376
Heat Shield Set-Up
376
Side-Stand Set-Up
377
Gearshift Pedal Set-Up
377
Special Tools
378
Tightening Torque
381
FI System and Intake Air System
382
Tightening Torque Chart
384
Service Data
385
Valve + Guide
385
Camshaft + Cylinder Head
385
Cylinder + Piston + Piston Ring
386
Conrod + Crankshaft
387
Transmission + Drive Chain
388
Thermostat + Radiator + Fan + Coolant
388
Injector + Fuel Pump + Fuel Pressure Regulator
389
FI Sensors + Secondary Throttle Valve Actuator
389
Wattage
391
Brake + Wheel
391
Tire
392
Suspension
392
Fuel + Oil
393
Wiring Diagram
394
For E-02, 28, 33
395
For E-02, 19
396
For E-24
397
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