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RF600 (1993)
Инструкция по эксплуатации Страница: 11

Suzuki RF600 (1993) [11/433] May 24 2002 15 02 gpo is09002 certified p 0 16

Содержание

985 3853 1
Erformance 1
Performance 1
Performance erformance 1
Performance motorcycle parts 1
Service manual 1
Suzuki 1
Service manual 2
Suzuki 2
Foreword 3
Group index 3
Important 3
Information 3
General information 5
Fuel oil and engine coolant recommendations 6
Serial number location 6
Suzuki rf600rr 94 model 6
Anti freeze eng1ne coolant 7
Brake fluid 7
Engine coolant 7
Engine oil 7
Front fork oil 7
Liquid amount of water engine coolant 7
Water for mixing 7
Break in procedures 8
Cylinder identification 8
General information 1 4 9
Matirial part page 9
May 24 2002 15 01 gpo 1809002 certified p 8 16 9
Special materials 9
The materials listed below are needed for maintenance work on the rf600r and should be kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants emery cloth and the like how to use them and where to use them are described in the text of this manual 9
General information 10
May 24 2002 15 01 gpo is09002 certified p 9 16 10
Ct i7i iki cauk afi 11
General information 1 6 11
May 24 2002 15 02 gpo is09002 certified p 0 16 11
Thread lock super 1360 99ûoo 3213o 11
Precautions and general instructions 12
Replacement parts 12
General information 1 8 13
Information labels 13
May 24 2002 15 02 gpo is09002 certified p 2 16 13
Information label for u s a model 14
May 24 2002 15 02 gpo is09002 certified p 0 16 14
S general information 14
Swingarm 14
Dimensions and dry mass 15
Engine 15
Specifications 15
Transmission 15
Capacities 16
Chassis 16
Electrical 16
Country or area 17
Periodic maintenance and 18
Tune up procedures 18
Periodic maintenance chart 19
Periodic maintenance schedule 19
Lubrication points 20
Air cleaner____________________________ 21
Exhaust pipe bolts 21
Maintenance and tune up procedures 21
Tappet clearance 22
May 24 2002 15 08 gp0 1808002 certified p 7 24 24
Periodic maintenance and tune up procedures 2 6 24
Tappet sh m no i12892 05co0 x x x tappet shim set no 112800 05820 24
Tappet shim selection table intake 24
7 periodic maintenance and tune up procedures ____________ 25
May 24 2002 15 08 gp0 1809002 certified p 8 24 25
Specified clearance 25
Tappet shim no 12892 05c0d x x x tappet shim set no 12800 05620 25
Tappet shim selection table exhaust 25
Spark plug 26
Engine oil and oil filter 27
Carburetor 28
Fuel filter 28
Clutch 29
Drive chain 29
Cooling system 31
Brake____________________ ____________ 32
Steering 35
Front fork 36
Rear suspension ___________________ 36
Chassis bolts and nuts 37
Compression pressure check 39
Compression test procedure 39
Oil pressure check 40
Oil pressure test procedure 40
Engine 42
Engine components removable with engine in place 43
Engine removal 44
Engine removal and reinstallation 44
Engine reinstallation 49
Engine disassembly 52
Fl 4 a jj 62
To ul zsv 62
Cylinder head service 63
Engine components inspection and service 63
Cylinder head distortion 64
Valve face wear 64
Valve head radial runout 64
Valve stem deflection 64
Valve stem runout 64
Valve guide servicing 65
Valve stem wear 65
Valve seat servicing 66
Valve seat width 66
Reassembly 68
Valve spring 68
Camshaft 69
Cam wear 70
Camshaft journal wear 70
Cam sprocket 71
Camshaft runout 71
Reassembly 71
Cam chain guide 72
Cam chain tensioner 72
Cylinder block distortion 72
Cylinder bore 73
Piston cylinder clearance 73
Piston diameter 73
Piston ring groove clearance 73
Piston ring free end gap and piston ring end gap 74
Conrod big end side clearance 75
Piston pin and pin bore 75
Conrod crank pin bearing selection 76
Bearing assembly 77
Crankcase crankshaft bearing selection 78
Crankshaft thrust clearance 80
Crankshaft runout 81
Clutch drive and driven plates 82
Clutch release bearing 82
Clutch release pinion and rack 82
Clutch spring free length 82
Oil pump 82
Transmission 83
Gearshift fork groove clearance 86
Engine reassembly 89
Fuel and lubrication system 109
Fuel system 110
Description 111
Fuel pump 111
Fuel pump inspection 112
Fuel pump removal 112
Fuel cock 113
Fuel cock mechanism 113
Fuel cock removal 113
Fuel filter removal 114
Fuel tank and fuel filter 114
Fuel tank removal 114
Inspection and cleaning 114
Carburetor 115
Construction 115
Fuel and lubrication system 4 fi 115
May 24 2002 17 09 gpo is09002 certified p 7 22 115
L d no location 116
Specifications 116
Diaphragm and piston operation 117
Slow system 118
Main system 119
Float system 120
Starter system 120
Disassembly 121
Removal 121
Float height adjustment 124
Inspection and adjustment 124
Needle valve inspection 124
Reassembly and remounting 124
Balance of carburetors 125
Lubrication system 127
Oil filter 127
Oil pressure 127
Oil sump filter 127
Engine lubrication system 129
Engine oil cooling system 130
Cooling system 131
Cooling system 132
Description 132
Construction 133
Cooling system 5 2 133
May 25 2002 01 07p from to 18472700197 133
Tightening torque 133
Cooling solution 135
Cooling system removal and disassembly 136
Radiator 136
Water hoses and thermostat case 136
Cooling fan 137
Engine coolant temperature gauge and cooling fan thermo switch 137
Thermostat 137
Water pump 137
Inspection 139
Installation 139
Radiator 139
Removal 139
Engine coolant temperature gauge 140
Inspection 140
Removal 140
Cooling fan 141
Cooling fan thermo switch 141
Inspection 141
Reassembly 141
Removal 141
Inspection 142
Reassembly 142
Removal 142
Inspection 143
Reassembly 143
Removal 143
Thermostat 143
Inspection 144
Reassembly 144
Removal and disassembly 144
Water pump 144
Electrical system 146
1 electrical system 147
Charging system 147
Description generator with ic regulator 147
Mry b5 b00b 01 35p from to 1b47b730197 psb ll 147
The generator features a solid state regulator that is mounted inside the generator all regulator com ponents are enclosed into a solid mold and this unit is attached to the brush holder frame the regu lator voltage setting cannot be adjusted two brushes carry current through the two slip rings to the rotor coil mounted on the rotor the stator windings are assembled on the inside of a laminated core that forms part of the generator housing a rectifier bridge connected to the stator windings contains six diodes and electrically changes the stator a c voltages to a d c voltage which appears at the generator output terminal 147
Charging output check 148
Removal and disassembly 148
Inspection 150
Mry b5 b00b 01 38p from to 18478730197 p 10 11 155
Reassembly information 155
Description 156
Ignition system digital ignitor 156
Inspection 157
Description 161
Removal and disassembly 161
Starter system 161
Inspection 162
Reassembly 163
Starter relay inspection 164
Description 165
May 25 2002 01 4bp from to 1b47b700197 p 165
Side stand ignition interlock system 165
The circuit consists of relay lamp diode and switches and decides to live the ignition coil depending on the position of the transmission and side stand with the neutral and side stand switches 165
The current flow turns on the relay and the ignition coil lives even the side stand 8 kept down this is or warming up the engine 165
This side stand ignition interlock system is to prevent starting the motorcycle with the side stand left down the system is operated by an electric circuit provided between the battery and ignition coil 165
Working mutually the ignition coil lives only in two situations as follows 1 transmission neutral on side stand down off 165
Inspection 166
Combination meter 168
Inspection 168
Removal and disassembly 168
23 electrical system 169
May 85 8008 01 50p from to 18478780157 p 169
Engine coolant temperature meter 170
Inspection 170
Fuel level indicator 171
Inspection 171
Headlight 173
Tail brake light 173
Oil pressure switch 174
Switches 174
Turn signal light 174
Side stand relay 175
Starter relay 175
Turn signal relay 175
Battery 176
Initial charging 176
Specifications 176
Servicing 177
Recharging operation 178
Chassis 179
1 chassis 180
Cowling and frame cover 180
May 25 2002 01 55p from to 18472700197 p 2 17 180
Removal 181
Front wheel 186
Removal 186
Inspection and disassembly 187
Reassembly and remounting 188
30 n m 190
Mry b5 b00b 01 5bp from to 1b47b730197 p 1b 17 190
Use old pan 190
Use old part 190
Chassis 7 12 191
May 25 2002 01 5bp from to 1b47b700197 2 10 17 191
Note mark the tire with chalk to note the positio 191
Of the tire 191
Of the tire on the rim and rotational directio 191
Remove the valve core from the valve stem and deflate 191
The most critical factor of a tubeless tire is the seal between the wheel nm and the tire bead be cause of this we recommend using a tire changer which is also more efficient than tire levers for tire removal the following tools are required 191
The tire completely 191
Tire and wheel 191
Tire removal 191
Inspection 193
Tire mounting 194
Brake pad replacement 196
Front brake 196
Caliper removal and disassembly 198
Caliper inspection 199
Caliper reassembly and remounting 199
Disc inspection 200
Disc servicing 200
Master cylinder removal and disassembly 200
Master cylinder inspection 201
Master cylinder reassembly and remounting 202
Front fork 203
Removal and disassembly 203
Reassembly and remounting 206
Front suspension setting std 208
Suspension setting 208
Removal and disassembly 209
Steering 209
Disassembly 210
Inspection 210
Reassembly and remounting 211
Steering tension adjustment 212
Ignition switch 213
Brake pad replacement 214
Rear brake 214
Caliper removal and disassembly 215
Caliper inspection 216
Caliper reassembly and remounting 217
Master cylinder removal and disassembly 217
Master cylinder inspection 218
Master cylinder reassembly and remounting 219
Rear wheel 220
Removal and disassembly 220
Inspection and disassembly 222
Reassembly and remounting 223
Rear suspension 226
Swingarm shock absorber and cushion lever 226
Removal 227
Inspection and disassembly 229
Reassembly and remounting 230
Cushion rods onto the swingarm 231
First of all assemble the shock absorber cushion lever and 231
Mry b5 b00b 02 isp from to 1b47b730197 pibb bb 231
Reassembly onto frame 231
Final inspection and adjustment 232
Suspension setting 232
Servicing information 233
Engine 234
Troubleshooting 234
Carburetor 237
Radiator 237
Electrical 238
Battery 239
Chassis 240
G green y yellow g y green with yellow tracer y b yellow with black tracer 242
Gr gray b br black with brown trecer o b orange with black tracer y g yellow with green tracer 242
La light green b bí black with blue tracer o g orange with green tracer 242
Lbl light blue b g black with green tracer o bi orange with blue tracer y w yellow with white tracer 242
Orange b r black with red tracer o r orange with red tracer 242
Wire color 242
В black p pink b w black with white tracer o w orange with white tracer 242
В blue r red b y black with yellow tracer o y orange with yellow tracer 242
Вт brown w white bl b blue with black tracer w b white with black tracer 242
B blue with black tracer 244
B w black with white tracer 244
B y black with yellow tracer 244
Blue r red 244
Br brown w white 244
G green y yellow 244
G y green with yellow tracer 244
Gr gray 9 br bieck with brown tracer 244
Him gioml 244
Lbl light blue влз black with green tracer 244
Lg light green b bi black with blue tracer 244
O b orange with black tracer 244
O bi orange with blue tracer 244
O r orange with red tracer 244
Oig orange with green tracer 244
Oiy orange with yellow tracer 244
Orange b r black with red tracer 244
Ow orange with white tracer 244
Switch 244
W b white with black tracer 244
Wire color 244
Y b yellow with black tracer 244
Y g yellow with green tracer 244
Y w yellow with white tracer 244
А ч1се м 244
В black p pink 244
Иеюпанг 244
Mñy 85 8008 02 06p from to 18478780157 p 245
Servicing information 8 12 245
Wire harness cable and hose routing 245
Wire harness routing 245
High tension cord routing 247
Cable routing 248
Fuel system hose routing 249
Cooling system hose routing 251
5 kg m 42 ib ftl 252
Air bleeder hole 252
Air cleaner water drain hose 252
Align the 252
Engine content overflow hose 252
Engine coolant 252
Engine coolant overflow hosa 252
Engine coolant overflow hose 252
Engine coolant reservoir 252
Faces upside 252
Fuel tank water drain hose 252
Oil cooler union bolt 252
Oil filter 252
Radiator 252
Radiator cap 252
Reservoir tank 252
Tank hosa 252
Thermostat 252
Tightening torque 59 n m 252
View from upper side 252
Water pump 252
Rear brake hose routing 254
Pair air supply system hose routing for california model 255
Frame cover set up 258
Lower cowling cushion 258
Mpy b5 b00b 03 05p from to 1b47b7301b7 259
Special tools 259
27 servicing information 260
May 85 8008 03 06p from to 18478730187 p 5 260
Note when ordering the special tool please confirm whether it is available or not 261
Servicing information r 2h 261
Engine 262
Tightening torque 262
Chassis 263
Tightening torque chart 264
Service data 265
Valve guide _______________________ univn hh 265
Camshaft cylinder head 266
Cylinder piston piston ring 266
Conrod crankshaft 267
Oil pump 267
Clutch 268
Thermostat 4 radiator fan 268
Transmission 4 drive chain 268
Carburetor 269
Electrical 269
Brake wheel 270
Wattage 270
Suspension 271
Fuel oil engine coolant 272
Tire pressure 272
Emission control informa tion 273
Emission control carburetor components 274
Evaporative emission control system only for california model 275
Canister hose routing only for california model 276
Pair air supply system hose routing only for california model 278
Carburetor 279
Contents 279
Exhaust pipe muffler mounting 10 15 279
Oil pan and oil sump filter 10 15 279
Rear brake cauper 10 15 279
Rf600rs 95 moded 279
Service data 279
Service information 10 12 279
Specifications 10 1 279
Starter clutch 10 12 279
Dimensions and dry mass 280
Engine 280
Specifications 280
Transmission 280
Capacities 281
Chassis 281
Electrical 281
Service data 282
Valve guide 282
Camshaft cylinder head ___________ unirmmjiro 283
Piston piston ring 283
Conrod crankshaft 284
Clutch___________________________________________________ 285
Oil pump 285
Thermostat radiator fan 285
Transmission drive chain _____________ 285
Carburetor 286
Electrical 287
Brake wheel 288
Wattage 288
Fuel oil engine coolant 289
Suspension 289
Tire pressure e 03 33 markets 290
Tire pressure the other markets 290
Service information 291
Starter clutch 291
Exhaust pipe muffler mounting 294
Oil pan and oil sump filter 294
Carburetor 295
Rear brake caliper 295
Contents 296
Rear brake and torque link rod 296
Rf600rt f 96 model 296
Service data 296
Service information 296
Specifications 296
May 25 2002 00 24p from to 18472700157 297
Rf8d0rt гэб мооец 297
Specifications 297
Service data 298
Valve guide 298
Camshaft cylinder head 299
Cylinder piston piston ring 299
Conrod crankshaft 300
Clutch 301
Oil pump 301
Thermostat radiator fan 301
Transmission drive chain 301
Carburetor 302
Electrical 303
Troiull 304
Fuel oil engine coolant 305
Suspension 305
Tire pressure e 03 33 markets 306
Tire pressure the other markets 306
Rear brake and torque link rod 307
Service information 307
Contents 308
Rf600rv 97 moded 308
Service data 308
Specifications 308
1 rf60orv 97 modeli 309
May 25 2002 00 esp from to 18472700157 309
Specifications 309
Service data 310
Cylinder head 311
Piston piston ring 311
Conrod crankshaft __________unh mm irn 312
Clutch 313
Oil pump 313
Thermostat i radiator fan 313
Transmission drive chain 313
Carburetor _____________________________ 314
Brake wheel _______________ _________ _____ 316
______ 316
Fuel oil engine coolant _______ 317
Suspension 317
33 markets 318
Tire pressure the other markets 318
Performance performance 319
Suzuki motor corporation 319
Suzuki motor corporation 320
I citalii 322
Ksttlpuqn 323
Hsclipnon 325
Kf no part xx 325
Пол 325
F no рыт мо 326
Remarks 326
Икс г 9 пк_____________________ 326
Dwription remarks 327
92 02 for explanation 328
Available fob thu model 328
Brgkt ftt7 328
Part number 328
Refer to parts bulletin 328
Tnth h a ì àaf l 328
W ho mr no urrion 328
Fectirioh 329
Cm sha 330
Fig л 330
Ip см 330
Remarks 330
O l оы 332
Ш иш 332
Aff no 333
Fig 11 333
Remarks 333
Fig 11 334
Oescwftiok 334
Fait mu 335
Fig 11 335
Kscription 335
Fig 12 336
Nipple 336
Fart mi 337
Fig 12 337
Fig 13 338
C o ot e o 339
Eta ci mm c at 339
Fi g j 4 339
Mm pmt mx kkiiptto wujk3 339
No 14 a 340
Renami kwuftiqr цг цр fact nd 340
Klw mt w cmftw baw 341
Wo ин г о 342
Сот юмо 342
Те 1iw эим 342
Юли mu ютю но п э trau 9 гом 342
Fig 17 343
Fig j 8 344
Kf no _f rr no description 344
Remarks 344
Ившк1 346
П0л9 346
Description 347
Fig 20 347
Ikf no ганг no 347
_________ истаю 347
Fig 21 348
Bearin 349
Ief no ют no 350
Й ия__________ 350
Р1ол2 350
Т п о тмммтт 350
Wb о nw 351
Л эсш 351
M ooji 352
Полз 352
Fig 24 353
Hkfiftion 353
N0 jmî no 353
Terarks 353
A tr 9 a 354
_________ wgum 354
Жпш1км m iwà 0n m 355
Fig 25 a 356
Fig 25 a 357
Fmt mx 357
F рыт nd 358
Kkflptiqn 358
Fig 27 359
Nd ht m tcsoryftiqh______________________ 359
Fmt ml 360
Fio 29 362
Hsciïftjon 362
Здю 363
Иадвсз______ 363
Поло 363
Тодгаом 363
Янюп о 363
Fig 31 364
Fig 32 365
Fig 3 3 366
Ref no part no description remarks 366
Fi6 m e 141 mmole switch 367
Fig 34 367
Ilicraicai i or ìqoi all 367
Iuarra 367
Kiakcmi o oi 367
Lewirs 367
Oesciiption 367
Part no 367
Pllnhb 0 04 367
Rfwort e3 367
Ш mil 367
Fig 36 369
Oillouol 369
String 370
___________iwi 370
Performance performance 371
Suzuki motor corporation 371

Suzuki RF600 (1993) [11/433] May 24 2002 15 02 gpo is09002 certified p 0 16

Содержание

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