![Suzuki RF600 (1993) [202/433] Master cylinder reassembly and remounting](/img/pdf.png)
Suzuki RF600 (1993) [202/433] Master cylinder reassembly and remounting
![Suzuki RF600 (1993) [202/433] Master cylinder reassembly and remounting](/views2/1121271/page202/bgca.png)
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
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MAY 25 2002 02 02P FROM 7 23 CHASSIS _____________ MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly Pay attention to the following points CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the compo nent to be inserted into the bore Specification and classification D0T4 When remounting the master cylinder on the handlebar align the master cylinder holder s mating surface 5 with punched mark 1 on the handlebar and tighten the upper clamp bolt first as shown Tightening torque 8 12 N m 0 8 1 2 kg m 6 0 8 5 lb ft CAUTION Bleed air from the system after reassembling master cylinder Refer to page 2 16 TO 18472700197 R 7
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