![Suzuki GSX-R600 (1996-2000) [11/429] Break in procedures](/img/pdf.png)
Suzuki GSX-R600 (1996-2000) [11/429] Break in procedures
![Suzuki GSX-R600 (1996-2000) [11/429] Break in procedures](/views2/1121286/page11/bgb.png)
Содержание
- 35ûé2 03 l 1
- Service manual 1
- Chassis 2
- Cooling system 2
- Electrical system 2
- Emission control informa tion 2
- Engine 2
- Foreword 2
- Fuel and lubrication system 2
- General informa tion 2
- Group index 2
- Gsx r600w 98 model 2
- Gsx r600x f 99 model 2
- Important 2
- Periodic maintenance 2
- Servicing information 2
- Suzuki motor corporation 2
- Component parts and work to be done 3
- How to use this manual 3
- To locate what you are looking for 3
- Symbol 4
- Ей 3 4
- Contents 6
- General informa tion 6
- General information 6
- Caution 7
- General precautions 7
- Warning 7
- Warning caution note 7
- Caution 8
- Fuel for canadian model 9
- Fuel for the other models 9
- Fuel for u s a model 9
- Fuel oil and engine coolant recommendation 9
- Serial number location 9
- Suzuki gsx r600v 97 model 9
- A caution 10
- Anti freeze engine coolant 10
- Brake fluid 10
- Engine coolant 10
- Engine oil for the other models 10
- Engine oil for u s a model 10
- Front fork oil 10
- Liquid amount of water engine coolant 10
- Warning 10
- Water for mixing 10
- Break in procedures 11
- Cylinder identification 11
- General information 1 6 12
- Information labels 12
- 7 general information_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 13
- Dimensions and dry mass 14
- Engine 14
- Specifications 14
- Transmission 14
- Capacities 15
- Chassis 15
- Electrical 15
- Country or area 16
- Contents 18
- Periodic maintenance 18
- Periodic maintenance chart 19
- Periodic maintenance schedule 19
- Lubrication points 20
- Air cleaner____________________________ 21
- Caution 21
- Maintenance and tune up procedures 21
- Spark plug 21
- Caution 22
- Tappet clearance 23
- 7 periodic maintenance 25
- Tappet shim n0 12892 05c00 x x x tappet shim set no 12800 05820 25
- Tappet shim selection table intake 25
- Periodic maintenance 2 b 26
- Shim size to be used 1 0 26
- Tappet shim no 1 2892 05c00 x x x tappet shim set no 12800 05820 26
- Tappet shim selection table exhaust 26
- ___ ______________ specified clearance no adjustment required 26
- Engine oil and oil filter 27
- Fuel hose 27
- Caution 28
- Engine idle speed 28
- Carburetor synchronization 29
- Clutch 29
- Throttle cable play 29
- Warning 29
- Caution 30
- Cooling system_________ 30
- Warning 30
- Drive chain 31
- Caution 32
- Caution 33
- Warning 33
- Caution 35
- A caution 36
- Steering 36
- Exhaust pipe bolts 37
- Front fork 37
- Rear suspension 37
- Chassis bolts and nuts 38
- Compression pressure check 40
- Compression test procedure 40
- Oil pressure check 41
- Oil pressure test procedure 41
- Contents 42
- Engine 42
- Engine components removable with engine in place 43
- Engine removal 44
- Engine removal and installation 44
- A caution 48
- Engine installation 49
- Bolt 1 85 mm 7 in 50
- Bolt 205 mm 8 in 50
- Bolt 30 mm 1 in 50
- Bolt 45 mm 1 in 50
- Bolt 55 mm 2 in 50
- Length 50
- Spacer 30 mm 1 in 50
- Camshaft cylinder head 54
- Contents 54
- Camshaft removal 55
- Caution 55
- Caution 56
- Cylinder head removal 56
- Camshaft cylinder head inspection and service 57
- Caution 57
- Caution 59
- Caution 65
- Warning 66
- Caution 67
- Caution 68
- Cylinder head installation 68
- Camshaft installation 69
- Caution 69
- Caution 71
- Caution 73
- Contents 74
- Cylinder piston 74
- Cylinder piston removal 75
- Cylinder piston inspection 76
- Piston cylinder installation 78
- Caution 80
- Clutch 82
- Contents 82
- Clutch removal 83
- Clutch inspection 85
- Clutch installation 86
- Caution 89
- Contents 92
- Oil pump removal and disassembly 93
- Caution 94
- Oil pump inspection 94
- Oil pump reassembly and installation 94
- Caution 95
- Caution 96
- Oil filter installation 96
- Oil filter removal 96
- Caution 97
- Oil cooler installation 97
- Oil cooler removal 97
- Inspection and cleaning 98
- Oil pan oil sump filter oil pressure regulator removal 98
- Oil pressure regulator oil sump filter oil pan installation 99
- Caution 100
- Oil pressure switch inspection 100
- Oil pressure switch installation 100
- Oil pressure switch removal 100
- Piston cooling oil nozzle inspection 100
- Piston cooling oil nozzle installation 100
- Piston cooling oil nozzle removal 100
- Starter system signal generator 102
- Starter clutch signal generator removal 103
- Starter clutch signal generator inspection 104
- Signal generator starter clutch installation 105
- Caution 106
- Starter motor inspection 107
- Starter motor installation 107
- Starter motor removal 107
- Contents 108
- Generator 108
- Generator inspection 109
- Generator removal 109
- Caution 110
- Generator installation 110
- Caution 111
- Contents 112
- Gearshift linkage 112
- Gearshift linkage inspection 113
- Gearshift linkage removal 113
- Caution 114
- Gearshift linkage installation 114
- Contents 116
- Carnkcase transmission crankshaft conrod 117
- Lower crankcase transmission removal 123
- Caution 125
- Caution 126
- Transmission inspection and service 126
- A caution 129
- Installation 132
- Lower crankcase transmission 132
- A caution 134
- Caution 135
- A caution 136
- Upper and middle crankcases crankshaft conrod removal 136
- Conrod crankshaft inspection 137
- Caution 139
- Piston cooling oil nozzle service 143
- Caution 144
- Upper and middle crankcases crankshaft conrod installation 144
- Caution 145
- Contents 148
- Fuel and lube system 148
- Fuel and lubrication system 148
- Fuel system 149
- Fuel tank 150
- Fuel tank lift up 150
- Fuel tank removal 150
- Warning 150
- A caution 151
- Vacuum fuel valve 151
- Caution 152
- Vacuum fuel valve inspection 152
- Vacuum fuel valve removal 152
- Warning 152
- Fuel pump and fuel filter 153
- Fuel pump inspection 153
- Warning 153
- Caution 154
- Fuel pump and fuel filter removal 154
- Warning 154
- Caution 155
- Fuel filter inspection and cleaning 155
- Fuel pump relay 155
- Inspection 155
- Carburetor 156
- Construction 156
- I d no location 157
- Specifications 157
- Diaphragm and piston operation 158
- Slow system 159
- Main system 160
- Float system 161
- Starter enrichener system 161
- Removal 162
- Caution 164
- Disassembly 164
- Caution 165
- A caution 166
- Caution 167
- Carburetor cleaning 168
- Caution 168
- Inspection 168
- Warning 168
- Warning 169
- Awarning 170
- Caution 171
- Reassembly and remounting 171
- Caution 172
- Carburetor synchronization 176
- A warning 178
- Caution 179
- Lubrication system 179
- Oil cooler 179
- Oil filter 179
- Oil pressure and oil pressure regulator 179
- Oil pump 179
- Oil sump filter 179
- Engine lubrication system chart 180
- Engine lubrication system 181
- Engine oil cooling system 182
- Contents 184
- Cooling system 184
- Cooling system 185
- Description 185
- Construction 186
- Cooling system 5 2 186
- Engine coolant 188
- Warning 188
- À caution 188
- Radiator and water hoses 189
- Removal 189
- Warning 189
- Caution 190
- Inspection 190
- Warning 190
- Remounting 191
- Cooling fan 192
- Inspection 192
- Remounting 192
- Removal 192
- Cooling fan thermo switch 193
- Removal 193
- Warning 193
- Caution 194
- Inspection 194
- Installation 194
- Engine coolant temperature gauge 195
- Removal 195
- Warning 195
- Caution 196
- Inspection 196
- Installation 196
- Inspection 197
- Removal 197
- Thermostat 197
- Warning 197
- Installation 198
- Removal and disassembly 199
- Warning 199
- Water pump 199
- Caution 200
- Inspection 201
- Reassembly and installation 201
- Chassis 204
- Contents 204
- 1 chassis 205
- Construction 205
- Exterior parts 205
- Removal 206
- Remounting 208
- Construction 209
- Front wheel 209
- Chassis 6 6 210
- Caution 211
- Inspection and disassembly 211
- Removal 211
- Caution 212
- Awarning 213
- Caution 213
- Reassembly and remounting 213
- Construction 215
- Front fork 215
- Removal and disassembly 216
- Caution 217
- Caution 218
- Caution 219
- Inspection 219
- Reassembly and remounting 219
- Caution 220
- Caution 222
- After installing the front fork adjust the spring pre load and damping force as follows 224
- Be sure to adjust the spring pre load and damping force on both front fork legs equally 224
- Damping force adjustment rebound side fully turn the damping force adjuster clockwise it is at stiffest position and turn it out to standard setting position std position 224
- Note before tightening the two axle pinch bolts on right front fork leg move the front fork up and down 4 or 5 times 224
- S turns out e 03 28 33 224
- Spring pre load adjustment there are seven grooved lines on the side of the spring ad juster position 0 provides the maximum spring pre load and position 7 provides the minimum spring pre load std position 4 224
- Standard front suspention setting 224
- Suspension setting 224
- Turn out others 224
- Warning 224
- Construction 225
- Removal and disassembly 225
- Remove both sides of the lower fairing refer to page 225
- Remove the front wheel refer to page 6 5 remove the front fork refer to page 6 11 225
- Steering 225
- Caution 227
- Inspection and disassembly 227
- Reassembly and remounting 228
- Steering tension adjustment 230
- Construction 231
- Rear wheel 231
- Caution 233
- Removal 233
- A caution 234
- Inspection and disassembly 234
- Caution 235
- Reassembly and remounting 235
- Construction 237
- Rear suspension 237
- Caution 239
- Removal 239
- Acautioixt 241
- Caution 241
- Inspection and disassembly 241
- Caution 242
- Caution 243
- Reassembly 243
- Remounting 244
- Final inspection and adjustment 246
- Suspension setting 246
- Construction 247
- Front brake 247
- Item nm kg m ib ft 247
- A caution_________________ ___________________ _______________________________ 248
- A caution___________________________________ 248
- Brake pad replacement 248
- Warning 248
- Acauti 249
- Brake fluid replacement 249
- Caliper removal and disassembly 249
- Caution 250
- A caution 251
- Caliper inspection 251
- Caliper reassembly and remounting 251
- Caution 251
- Caution 252
- Disc servicing 252
- Master cylinder removal and disassembly 252
- Caution 254
- Master cylinder inspection 254
- Master cylinder reassembly and remounting 254
- Caution 255
- Construction 255
- Rear brake 255
- Warning 255
- Brake pad replacement 256
- Caution 256
- Brake fluid replacement 257
- Caliper removal and disassembly 257
- Caution 257
- Warning 257
- Acaution 258
- Caliper inspection 258
- Caliper reassembly and remounting 258
- Caution 258
- A caution 259
- Master cylinder removal and disassembly 259
- Caution 260
- Disc servicing 260
- Master cylinder inspection 260
- Master cylinder reassembly and remounting 260
- Tire and wheel 261
- Tire removal 261
- Inspection 263
- Acaution 264
- Tire installation 264
- Warning 265
- Contents 266
- Electrical system 266
- Cautions in servicing 267
- Connector 267
- Coupler 267
- Semi conductor equipped part 267
- Battery 268
- Caution 268
- Connecting battery 268
- Using multi circuit tester 268
- Wiring procedure 268
- Location of electrical components 269
- Charging system 271
- Description 271
- Troubleshooting 273
- Caution 274
- Inspection 274
- A caution 275
- Acaution 275
- 25008 multi circuit tester set 276
- 3 and 4 276
- A caution 276
- Disconnect the regulator rectifier couplers 276
- Electrical system 7 10 276
- Note if the tester read under 1 4v replace the battery of multi circuit tester when do not connecting the tester probes 276
- Regulator rectifier checking with multi circuit tester remove the seats and the frame cover refer to pages 276
- Sj tester knob indication diode test m 276
- Unit v 276
- Using the multi circuit tester measure the voltage between the lead wires in the following table if the voltage is incor rect replace the regulator rectifier 276
- When using the multi circuit tester follow the instruc tion manual 276
- Side stand ignition interlock system description 277
- Starter system and side stand ignition interlock system 277
- Starter system description 277
- Electrical system 7 12 278
- Side stand up right on 278
- 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 working mutually the ignition coil lives only in two situations as follows 1 transmission neutral on side stand down off 278
- The current flow turns on the relay and the ignition coil lives even the side stand is kept down this is or warming up the engine 278
- The current flow turns on the relay and the ignition coil lives the engine can be easily started at any transmission position 278
- Troubleshooting 279
- Starter motor 280
- Acaution 281
- Caution 283
- Starter relay inspection 283
- Side stand ignition interlock system part inspection 284
- A caution 286
- Converter 286
- Description 286
- Ignition system 286
- Troubleshooting 287
- A caution 288
- Inspection 288
- Caution 289
- Warning 289
- Caution 290
- Warning 290
- Caution 291
- Warning 291
- Caution 292
- Caution 294
- A caution 295
- Awarning 295
- Combination meter 296
- Disassembly 296
- Removal 296
- Electrical system 297
- Inspection 297
- Using the tester check the continuity between terminals in the following diagram if the continuity measured is incor rect remove and check the bulb if the bulb is failure install the new bulb and check the con tinuity again if the bulb is correct replace the unit with a new one 297
- A caution 302
- Headlight 302
- Tail brake and turn signal light 303
- O о o 304
- Switches 304
- Battery 305
- Fuel pump relay 305
- Initial charging 305
- Side stand relay 305
- Specifications 305
- Starter relay 305
- Turn signal relay 305
- A caution 307
- Recharging operation 307
- Servicing 307
- Contents 308
- Servicing info 308
- Servicing information 308
- Engine 309
- Troubleshooting 309
- Carburetor 312
- Radiator 312
- Chassis 313
- Brakes 314
- Electrical 315
- Battery 316
- Шпк 317
- Servicing information 8 10 318
- Tötet 1 318
- И гп г 318
- Елки 319
- Servicing information 8 12 320
- Лен 320
- Wire harness cable and hose routing 321
- Wire harness routing 321
- Servicing information 8 14 322
- Servicing information 323
- Cable routing 324
- Servicing information 8 16 324
- Fuel system hose routing 325
- I z cx 326
- Cooling system hose routing 327
- Servicing information 327
- Front brake hose routing 328
- Rear brake hose routing 329
- Servicing information 329
- Pair air supply system hose routing for e 18 33 and 39 models 330
- Inside of fairing 333
- Lower fairing cushion and heat shield 333
- Servicing information 333
- Servicing information 8 26 334
- Special tools 334
- Servicing information 335
- Note when ordering the special tool please confirm whether it is available or not 336
- Servicing information 8 28 336
- Engine 337
- Tightening torque 337
- Chassis 338
- For other bolts and nuts listed previously refer to this chart 339
- Tightening torque chart 339
- Service data 340
- Valve guide 340
- Camshaft cylinder head 341
- Cylinder piston piston ring 341
- Conrod crankshaft 342
- Oil pump 342
- Clutch 343
- Thermostat radiator fan 343
- Transmission drive chain 343
- Carburetor 344
- Electrical 345
- Brake wheel 346
- Wattage 346
- Suspension 347
- Tire pressure 347
- Fuel oil engine coolant 348
- Contents 350
- Emission control info 350
- Emission control information 350
- Emission control carburetor components 351
- Emission control information 9 2 352
- Evaporative emission control system california model only 352
- Fresh air 352
- Hc vapor 352
- I fuel 352
- Canister hose routing california model only 353
- Canister 354
- Evaporative emission control system inspection california model only 354
- From the side there should be flow out through the purge control valve 354
- From the side there should be no flow through the purge control valve 354
- If operation differs from that listed above the purge con 354
- Inspect the canister for damage of the body 354
- Inspect the hoses for wear or damage inspect that the hoses are securely connected 354
- Inspect the purge control valve for damage of the body inspect the purge control valve operation as following procedure 354
- Note when the purge control valve is connected to the hose the side should be pointed toward the carburetor side and the side should be pointed toward the canister side 354
- Purge control valve 354
- Remove the fuel tank 354
- Remove the seats and frame cover refer to pages 6 3 354
- Trol valve must be replaced 354
- Warning 354
- When air pressure is applied to the purge control valve 354
- Hoses and pipes 357
- Pair air supply system inspection california model only 357
- Pair cleaner 357
- Pair reed valve 357
- A caution 358
- Pair control valve 358
- Foreword 360
- Group index 360
- Gsx r600w 98 model 360
- Model updates 360
- General information 362
- Dimensions and dry mass 363
- Engine 363
- Specifications 363
- Transmission 363
- Capacities 364
- Chassis 364
- Electrical 364
- Country and area codes 365
- Periodic maintenance 366
- Periodic maintenance chart 367
- Periodic maintenance schedule 367
- Maintenance and tune up procedures 368
- Maintenance procedures 368
- Throttle cable play 368
- Warning 368
- Carburetor synchronization 369
- Evaporative emission control system california model only 369
- Pair air supply system california model only 369
- Engine 370
- Camshaft 371
- Camshaft cylinder head 371
- Engine removal and installation 371
- Gearshift shaft bushing 371
- Camshaft cylinder head installation 372
- Clutch 373
- Clutch drive and driven plates inspection 373
- Clutch plates installation 373
- Cylinder piston 373
- Piston installation 373
- A caution ___________ _________ 374
- A caution_________________________ 374
- Crankcase transmission crankshaft conrod 374
- Engine lubrication system 374
- Neutral position indicator switch installation 374
- Oil pump installation 374
- Starter clutch cover installation 374
- Starter system signal generator 374
- Crankcase crankshaft bearing selection 375
- A caution ____ 376
- Lower crankcase transmission installation 376
- Upper and middle crankcases crankshaft conrod installation 377
- Fuel and lubrication system 378
- Carburetor 379
- Main air control system 379
- Solenoid valve inspection 380
- Solenoid valve voltage inspection 380
- Funnel installation 381
- Solenoid valve installation 381
- Chassis 382
- A warning 383
- Front fork 383
- Reassembly 383
- Suspension setting 383
- Compression side fully turn the damping force adjuster 2 clockwise it is at stiffest position and turn it out to standard setting position std position is 1 384
- Damping force adjustment rebound side fully turn the damping force adjuster clockwise it is at stiffest position and turn it out to standard setting position std position is 1 turn out 384
- G turns out 384
- Rear suspension 384
- Rear suspension setting table 384
- Spring pre load adjustment the set length 190 mm 7 in provides the maximum spring pre load the set length 200 mm 7 in provides the minimum spring pre load std length 195 mm 7 in 384
- Suspension setting 384
- Electrical system 386
- Diode inspection 387
- Side stand relay inspection 387
- Turn signal relay operation check 387
- Turn signal side stand relay 387
- Servicing information 388
- Wiring diagram 389
- Gsx r600w c98 model 10 8 2 390
- Wire colors 390
- 8 3 gsx r600w 98 model 391
- О q d 391
- For e 24 model 392
- M to to 393
- Service data 396
- Valve guide 396
- Camshaft cylinder head 397
- Cylinder piston piston ring 397
- Conrod crankshaft 398
- Oil pump 398
- Clutch 399
- Thermostat radiator fan 399
- Transmission drive chain 399
- Carburetor 400
- Electrical 401
- Brake wheel 402
- Wattage 402
- Suspension 403
- Tire pressure 403
- Fuel oil coolant 404
- Emission control info 406
- Emission control information 406
- Pair air supply system diagram 407
- Gsx r600w 98 m0del 10 9 2 408
- Pair air supply system hose 408
- Routing 408
- Sbxx s 408
- X u wj k 408
- Hoses and pipes 409
- Pair air supply system inspection 409
- Pair cleaner 409
- Pair control valve 409
- Foreword 410
- Gsx r600x 99 model 410
- Model updates 410
- Dimensions and dry mass 411
- Engine 411
- Specifications 411
- Transmission 411
- Capacities 412
- Chassis 412
- Electrical 412
- Service data 413
- Valve guide 413
- Camshaf 414
- Cylinder head 414
- Cylinder piston piston ring 414
- Conrod crankshaft 415
- Oil pump 415
- Clutch 416
- Thermostat radiator fan 416
- Transmission drive chain 416
- Carburetor 417
- Electrical 418
- Brake wheel 419
- Wattage 419
- Suspension 420
- Tire pressure 420
- Fuel oil coolant 421
- Engine 422
- Tightening torque 422
- Cam chain tension adjuster 423
- Special tool 423
- Clutch 424
- Clutch drive and driven pates inspection 424
- 15 gsx r600x 99 model 425
- Engine oil cooler 425
- Engine oil cooling system 425
- The oil cooler has been changed as follows when installing the oil cooler tighten its union bolt to the specified torque 425
- Engine lubrication system chart 426
- Gsx r600x 99 model 11 16 426
- Sub gallery 426
- Carburetor funnel installation only for e 03 24 28 and 33 models 427
- Solenoid valve voltage inspection only for e 03 24 28 and 33 models 427
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1 5 GENERAL INFORMATION BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before sub jecting the engine to maximum stresses The future performance and reliability of the engine de pends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial Up to 1 Over 1 800km 500 600km 1000 600km 1000 miles Below 6 500 r min miles Below 10 000 r min miles Below 13 400 r min Upon reaching an odometer reading of 1 600 km 1 000 miles you can subject the motorcycle to full throttle operation However do not exceed 13 400 r min at any time CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No 1 No 2 No 3 and No 4 cylinder as counted from left to right as viewed by the rider on the seat
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