![Suzuki GSX-R600 (2001-2002) [2/399] Electrical system](/img/pdf.png)
Suzuki GSX-R600 (2001-2002) [2/399] Electrical system
![Suzuki GSX-R600 (2001-2002) [2/399] Electrical system](/views2/1121300/page2/bg2.png)
Содержание
- Gsx r600 1
- Cooling and lubrication system 2
- Electrical system 2
- Fl system and intake air system 2
- Foreword 2
- General information 2
- Group index 2
- Periodic maintenance 2
- Servicing information 2
- Wiring diagram 2
- Component parts and work to be done 3
- Howto use this manual 3
- To locate what you are looking for 3
- Abbreviations may be used in this manual 5
- General information 8
- General precautions 9
- Warning caution note 9
- Serial number location 11
- Suzuki gsx r600k1 2001 model 11
- Brake fluid 12
- Engine oil for the other models 12
- Engine oil for u s a model 12
- Front fork oil 12
- Fuel for the other countries 12
- Fuel for usa and canada 12
- Fuel oil and engine coolant recommendation 12
- Anti freeze engine coolant 13
- Break in procedures 13
- Cylinder identification 13
- Engine coolant 13
- Liquid amount of water engine coolant 13
- Water for mixing 13
- Information labels 14
- Specifications 15
- Country and area codes 17
- Periodic maintenance 18
- Periodic maintenance chart 19
- Periodic maintenance schedule 19
- Lubrication points 20
- Air cleaner 21
- Maintenance and tune up procedures 21
- Spark plug 22
- Valve clearance 25
- Column 28
- Example 28
- How to use this chart 28
- I measure valve clearance engine is cold 28
- Ii measure present shim size 28
- Periodic maintenance 2 11 28
- Present shim size 1 0 mm 28
- Shim size to be used 1 0 mm 28
- Tappet shim no 12892 05c00 xxx 28
- Tappet shim selection table intake 5 28
- Tappet shim set 12800 05820 y 28
- Valve clearance is 0 3 mm 28
- 12 periodic maintenance 29
- Column 29
- Example 29
- Horizontal 29
- I l к 29
- Ii measure present shim size 29
- Iii match clearance in vertical column with present shim size in 29
- Measure valve clearance engine is cold 29
- Present shim size 29
- Shim size to be used 29
- Tappet shim no 12892 05c00 xxx 29
- Tappet shim selection table exhaust 29
- Tappet shim set 12800 05820 29
- Valve clearance is 29
- Engine oil and oil filter 30
- Engine idle speed 32
- Fuel hose 32
- Throttle valve synchronization 32
- Throttle cable play 33
- Clutch 34
- Cooling system 35
- Drive chain 37
- Cautio 38
- Steering 43
- Exhaust pipe bolt and nut 44
- Front fork 44
- Rear suspension 44
- Chassis bolts and nuts 45
- Compression pressure check 47
- Compression test procedure 47
- Oil pressure check 48
- Engine 50
- Engine center 51
- Engine components removable with engine in place 51
- Engine left side 51
- Engine right side 51
- Engine removal 52
- Engine removal and reinstallation 52
- Engine reinstallation 60
- Engine disassembly 64
- Engine components inspection and service 77
- Pair valve 77
- Camshaft 78
- Cylinder head cover 78
- Cam chain guide 80
- Cam chain tension adjuster 80
- Cam chain tensioner 80
- Cylinder head and valve 81
- Clutch 91
- Generator 92
- Oil pump 92
- Starter clutch 92
- Water pump 92
- Gearshift system 93
- Oil pressure regulator 94
- Oil strainer 94
- Transmission 95
- Transmission parts location 97
- Cylinder 98
- Piston and piston ring 99
- Crankcase 102
- Crankshaft and conrod 108
- Crankshaft journal bearing 111
- Crankshaft thrust bearing 113
- Engine reassembly 115
- Crankshaft 117
- Clutch 136
- Fl system and intake air system 147
- Fuel injection and air intake system 147
- Connector coupler 149
- Precautions in servicing 149
- Ecm various sensors 150
- Electrical circuit inspection procedure 151
- Using testers 154
- Fl 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 injector 159
- Fuel pressure regulator 159
- Fuel pump control system 160
- Ecm fl control unit 161
- D y d 1 d 162
- Sensors 163
- Intake air system 167
- Secondary throttle control system 167
- Operation 168
- Fl system diagram 171
- Fl system wiring diagram 172
- Self diagnosis function 173
- User mode 173
- Dealer mode 174
- Fail safe function 176
- Customer complaint analysis 177
- Fl system trouble shooting 177
- Self diagnosis reset procedure 178
- Self diagnostic procedures 178
- Malfunction code and defective condition 179
- C11 cmp sensor circuit malfunction 181
- C12 ckp sensor circuit malfunction 182
- I i m rm i 182
- C13 iap sensor circuit malfunction 183
- 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
- I v i i 191
- C24 c25 c26 or c27 ignition system malfunction 192
- C28 stv actuator circuit malfunction 192
- C29 stp sensor circuit malfunction 193
- C30 stc unit circuit malfunction 195
- Ntitrm rrntiti 195
- C31 gear position gp switch circuit malfunction 196
- Fi i i i i m n m i 196
- C32 c33 c34 or c35 fuel injection malfunction 197
- C41 fp relay circuit malfunction 198
- C42 ig switch circuit malfunction 198
- Fuel system 199
- Fuel tank installation 199
- Fuel tank lift up 199
- Fuel tank removal 199
- Fuel pressure inspection 200
- Fuel pump inspection 201
- Fuel pump and fuel filter removal 203
- Fuel pump relay inspection 203
- Fuel mesh filter inspection and cleaning 205
- Fuel pump and fuel mesh filter installation 205
- Construction 208
- Throttle body and stv actuator 208
- Air cleaner box and throttle body removal 209
- Throttle body disassembly 211
- Inspection 213
- Throttle body cleaning 213
- Throttle body reassembly 214
- Throttle body installation 217
- Stp sensor adjustment 218
- Fast idle adjustment 219
- Fuel injector inspection 219
- Fuel injector installation 219
- Fuel injector removal 219
- Throttle valve synchronization 220
- Throttle cable adjustment 223
- Throttle position sensor tps setting 223
- Ckp sensor inspection 224
- Ckp sensor removal installation 224
- Cmp sensor inspection 224
- Cmp sensor removal installation 224
- Iap sensor inspection 224
- Iap sensor removal installation 224
- Iat sensor inspection 224
- Iat sensor removal installation 224
- Sensors 224
- Tp sensor inspection 224
- Tp sensor removal installation 224
- Ap sensor inspection 225
- Ap sensor removal installation 225
- Ect sensor inspection 225
- Ect sensor removal installation 225
- Stp sensor inspection 225
- Stp sensor removal installation 225
- To sensor inspection 225
- To sensor removal installation 225
- Cooling and lubrication system 226
- Cooling lube system 226
- Engine coolant 227
- Cooling circuit 228
- Cooling circuit inspection 228
- Radiator and water hoses 229
- Radiator cap inspection 229
- Radiator inspection and cleaning 229
- Radiator removal 229
- Radiator remounting 230
- Water hose inspection 230
- Cooling fan 231
- Cooling fan thermo switch 231
- Inspection 231
- Installation 231
- Removal 231
- Inspection 232
- Installation 232
- Engine coolant temperature sensor 233
- Inspection 233
- Removal 233
- Installation 234
- Removal 234
- Thermostat 234
- Inspection 235
- Installation 235
- Removal and disassembly 236
- Water pump 236
- Inspection 239
- Reassembly and installation 240
- Lubrication system 243
- Engine lubrication system chart 244
- Cooling and lubrication system 5 21 246
- View of a 246
- 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
- Cowling brace 252
- Right and left air intake pipes 252
- Frame cover 253
- Front seat 253
- Rear seat and seat tail cover 253
- Construction 254
- Front wheel 254
- Inspection and disassembly 255
- Removal 255
- Reassembly and remounting 257
- Construction 260
- Front fork 260
- Removal and disassembly 261
- Inspection 264
- Reassembly and remounting 265
- Suspension setting 270
- Construction 271
- Inspection 271
- Remounting 271
- Removal 271
- Steering damper 271
- Chassis 6 25 272
- Construction 272
- Removal and disassembly 272
- Remove the front wheel czf6 8 remove the front fork c 272
- Steering 272
- Inspection and disassembly 274
- Reassembly and remounting 274
- Steering tension adjustment 276
- Construction 277
- Handlebar 277
- Removal and disassembly 277
- Reassembly and remounting 278
- Construction 280
- Rear wheel 280
- Removal 281
- Inspection and disassembly 282
- Reassemble and remount the rear wheel in the reverse order of removal and disassembly pay attention to the following points 284
- Reassembly and remounting 284
- Construction 288
- Rear shock absorber 288
- Inspection 289
- Removal 289
- Rear shock absorber scrapping procedure 290
- Remounting 290
- Suspension setting 291
- Chassis 6 45 292
- Rear suspension construction 292
- Removal 293
- Inspection and disassembly 295
- Reassembly 297
- Remounting 299
- Final inspection and adjustment 300
- Construction 301
- Front brake 301
- Brake fluid replacement 302
- Brake pad replacement 302
- Caliper removal and disassembly 303
- Caliper inspection 304
- Caliper reassembly and remounting 304
- Brake disc inspection 305
- Master cylinder removal and disassembly 306
- Master cylinder inspection 307
- Master cylinder reassembly and remounting 307
- Construction 309
- Rear brake 309
- Brake fluid replacement 310
- Brake pad replacement 310
- Caliper removal and disassembly 311
- Cautio 311
- Caliper inspection 312
- Caliper reassembly and remounting 312
- Master cylinder removal and disassembly 313
- Master cylinder inspection 314
- Master cylinder reassembly and 314
- Remounting 314
- Inspection 315
- Tire and wheel 315
- Tire removal 315
- Tire installation 316
- Valve inspection 316
- Valve installation 316
- Balancer weight 317
- Electrical system 318
- Cautions in servicing 319
- Connector 319
- Coupler 319
- Semi conductor equipped part 319
- Battery 320
- Connecting the battery 320
- Using the multi circuit tester 320
- Wiring procedure 320
- Location of electrical components 321
- Charging system 323
- Troubleshooting 323
- Inspection 324
- 6 disconnect the regulator rectifier coupler measure the voltage between the lead wires using the multi cir cuit tester as indicated in the table below if the voltage is not within the specified value replace the regulator rectifier with a new one 326
- F 09900 25008 multi circuit tester set 326
- More than 1 v tester s battery voltage 326
- Note if the tester reads under 1 v when the tester probes are not connected replace the battery of multi circuit tester 326
- Regulator rectifier remove the frame cover c 326
- Tester knob indication diode test m 326
- Unit v 326
- Starter system and side stand ignition interlock system 327
- Troubleshooting 327
- Starter motor removal and disassembly 328
- _____1__ 328
- Starter motor inspection 329
- Starter motor reassembly 329
- Starter relay inspection 330
- Side stand ignition interlock system parts inspection 331
- Ignition system 334
- Troubleshooting 334
- Inspection 336
- Secondary throttle control unit 339
- Combination meter 340
- Description 340
- Removal and disassembly 341
- Inspection 342
- Headlight brake light taillight and turn signal light 346
- Fuel pump relay 347
- Relays 347
- Starter relay 347
- Switches 347
- Turn signal side stand relay 347
- И о и 348
- Battery 349
- Initial charging 349
- Specifications 349
- Servicing 350
- Recharging operation 351
- Servicing information 352
- Fl system malfunction code and defective condition 353
- Troubleshooting 353
- Engine 355
- Chassis 361
- Brakes 362
- Electrical 363
- Battery 364
- Wiring harness cable and hose routing 365
- Wiring harness routing 365
- View d 366
- Detail a 368
- Detail b 368
- Fuel tank drain hose routing 369
- Align the marking 370
- With the lib of pipe 370
- Pair air supply system hose routing 373
- 24 servicing information 375
- Frame cover set up 376
- Heat shield set up 376
- Gearshift pedal set up 377
- Side stand set up 377
- Special tools 378
- Note when order the special tool please confirm whether it is available or not 380
- Engine 381
- Tightening torque 381
- Cooling system 382
- Fl system and intake air system 382
- Chassis 383
- Tightening torque chart 384
- Camshaft cylinder head 385
- Service data 385
- Valve guide_________________ 385
- Cylinder piston piston ring 386
- Clutch___________________________________ 387
- Conrod crankshaft 387
- Oil pump 387
- Thermostat radiator fan coolant 388
- Transmission drive chain 388
- Fl sensors secondary throttle valve actuator 389
- Injector fuel pump fuel pressure regulator 389
- Electrical 390
- Throttle body 390
- Brake wheel 391
- Wattage 391
- Suspension 392
- Fuel oil 393
- Fl system wiring diagram 394
- Wiring diagram 394
- Wiring diagrams 394
- For e 03 28 33 395
- Handle switch l 395
- Handle switch r 395
- Wiring diagram 395
- For e 02 19 396
- Handle switch l 396
- Handle switch r 396
- For e 24 397
- Suzuki motor corporation 399
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FOREWORD This manual contains an introductory description on the SUZUKI GSX R600 and procedures for its inspection service and overhaul of its main com ponents Other information considered as generally known is not included Read the GENERAL INFORMATION section to fa miliarize yourself with the motorcycle and its mainte nance Use this section as well as other sections to use as a guide for proper inspection and service This manual will help you know the motorcycle bet ter so that you can assure your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of pub lication If modifications have been made since then differences may exist between the content of this manual and the actual motor cycle Illustrations in this manual are used to show the basic principles of operation and work pro cedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motor cycles If you do not have the proper knowl edge and tools ask your authorized SUZUKI motorcycle dealer to help you GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE 3 Fl SYSTEM AND INTAKE AIR SYSTEM COOLING AND LUBRICATION SYSTEM 6 ELECTRICAL SYSTEM 7 SERVICING INFORMATION 8 WIRING DIAGRAM A WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger SUZUKI MOTOR CORPORATION Motorcycle Service Department
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