Suzuki GSX-R400, GSX-R600 Repair Service Manual 1997-2008
Complete service repair manual with Electrical Wiring Diagrams for Suzuki GSX-R400, GSX-R600, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki GSX-R400, GSX-R600 Motorcycles workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Suzuki GSX-R400 (GK71B, GK71F) Service Manual 1984-1987.pdf
Suzuki GSX-R600 (GSX-R600V, GSX-R600W, GSX-R600X) Service Manual '97-'00 (EN).pdf
Suzuki GSX-R600K6 Service Manual '06 (EN).pdf
Suzuki GSX-R600K6 Service Manual '06 (SPANISH).pdf
Suzuki GSX-R600K8 Service Manual '08 (EN).pdf
Suzuki GSX-R600 Service Manual '04-'05 (EN).pdf
Suzuki GSX-R600 Service Manual '01-'02 (EN).pdf
PRODUCT DETAILS:
Total Pages: 3,221 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Suzuki GSX-R400 (GK71B, GK71F) Service Manual 1984-1987...2
Suzuki GSX-R600 (GSX-R600V, GSX-R600W, GSX-R600X) Service Manual '97-'00 (EN)...248
Cover...248
Index...249
1. General Information...253
2. Periodic Maintenance...265
3. Engine...289
4. Fuel and Lube System...395
5. Cooling System...431
6. Chassis...451
7. Electrical System...513
8. Servicing Info...555
9. Emission Control Info...597
10. 1998 Model Updates...607
Specs...610
Periodic Maintenance...613
Maintenance Procedures...615
Engine...617
Chassis...629
Electrical System...633
Servicing Information...635
Wiring Diagram...636
Service Data...643
Emission Control Info...653
1999 Model Updates...657
Specifications...658
Cam Chain Tension Adjuster...670
Clutch...671
Engine Oil Cooler...672
Suzuki GSX-R600 Service Manual '04-'05 (EN)...677
Suzuki GSX-R600 Service Manual '01-'02 (EN)...1142
Cover...1142
Index...1143
1. General Information...1149
2. Periodic Maintenance...1159
3. Engine...1191
4. Fuel Injection and Air Intake System...1288
5. Cooling & Lube System...1367
6. Chassis...1388
7. Electrical System...1459
8. Servicing Information...1493
Wiring Diagrams...1535
Suzuki GSX-R600K6 Service Manual '06 (EN)...1541
99500-35100-01E GSX-R600 SERVICE MANUAL...1541
00 FOREWORD_GROUP INDEX...1542
HOW TO USE THIS MANUAL...1543
TO LOCATE WHAT YOU ARE LOOKING FOR:...1543
COMPONENT PARTS AND WORK TO BE DONE...1543
SYMBOL...1544
ABBREVIATIONS USED IN THIS MANUAL...1545
01 GENERAL INFORMATION...1548
COUNTRY AND AREA CODES...1548
WARNING/CAUTION/NOTE...1549
GENERAL PRECAUTIONS...1549
SUZUKI GSX-R600K6 (’06-MODEL)...1551
SERIAL NUMBER LOCATION...1551
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...1552
BREAK-IN PROCEDURES...1554
CYLINDER IDENTIFICATION...1554
INFORMATION LABELS...1555
SPECIFICATIONS...1556
02 PERIODIC MAINTENANCE...1558
PERIODIC MAINTENANCE SCHEDULE...1559
MAINTENANCE AND TUNE-UP PROCEDURES...1561
COMPRESSION PRESSURE CHECK...1589
OIL PRESSURE CHECK...1590
SDS CHECK...1591
03 ENGINE...1594
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...1595
ENGINE REMOVAL AND INSTALLATION...1596
ENGINE DISASSEMBLY...1607
ENGINE COMPONENTS INSPECTION AND SERVICE...1619
ENGINE REASSEMBLY...1663
04 FI SYSTEM DIAGNOSIS...1692
PRECAUTIONS IN SERVICING...1694
FI SYSTEM TECHNICAL FEATURES...1701
ECM TERMINAL...1706
SELF-DIAGNOSIS FUNCTION...1708
FAIL-SAFE FUNCTION...1712
FI SYSTEM TROUBLESHOOTING...1714
SENSORS...1796
05 FUEL SYSTEM AND THROTTLE BODY...1799
FUEL DELIVERY SYSTEM...1800
FUEL SYSTEM...1801
THROTTLE BODY...1811
06 EXHAUST SYSTEM...1826
EXHAUST SYSTEM...1827
EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)...1829
07 COOLING AND LUBRICATION SYSTEM...1840
ENGINE COOLANT...1841
COOLING CIRCUIT...1842
RADIATOR AND WATER HOSES...1843
COOLING FAN...1845
ECT SENSOR...1846
THERMOSTAT...1848
WATER PUMP...1850
LUBRICATION SYSTEM...1856
08 CHASSIS...1861
EXTERIOR PARTS...1863
FRONT WHEEL...1869
FRONT FORK...1877
STEERING DAMPER...1888
STEERING...1890
HANDLEBARS...1896
REAR WHEEL...1900
REAR SHOCK ABSORBER...1908
REAR SUSPENSION...1914
FRONT BRAKE...1924
REAR BRAKE...1935
TIRE AND WHEEL...1945
DRIVE CHAIN...1949
09 ELECTRICAL SYSTEM...1953
CAUTIONS IN SERVICING...1955
LOCATION OF ELECTRICAL COMPONENTS...1958
CHARGING SYSTEM...1960
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...1964
IGNITION SYSTEM...1972
COMBINATION METER...1981
LAMPS...1987
RELAYS...1989
BATTERY...1992
10 SERVICING INFORMATION...1995
TROUBLESHOOTING...1996
WIRING HARNESS, CABLE AND HOSE ROUTING...2011
TIGHTENING TORQUE...2031
SERVICE DATA...2035
11 EMISSION CONTROL INFORMATION...2045
EMISSION CONTROL SYSTEMS...2046
PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION...2050
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...2052
HO2 SENSOR INSPECTION (For E-02, 19)...2053
12 WIRING DIAGRAM...2054
Suzuki GSX-R600K6 Service Manual '06 (SPANISH)...2058
GSX-R600 MANUAL DE SERVICIO...0
PREAMBULO_INDICE...2058
CÓMO UTILIZAR ESTE MANUAL...2059
PARA LOCALIZAR LO QUE BUSCA:...2059
DESPIECE DE COMPONENTES Y TAREAS A REALIZAR...2059
SÍMBOLO...2060
ABREVIATURAS UTILIZADAS EN ESTE MANUAL...2061
01 INFORMACION GENERAL...2064
ADVERTENCIA/PRECAUCIÓN/NOTA...2065
PRECAUCIONES GENERALES...2065
SUZUKI GSX-R600K6 (MODELO ’06)...2067
LOCALIZACIÓN DEL NÚMERO DE SERIE...2067
COMBUSTIBLE, ACEITE, Y REFRIGERANTE DEL MOTOR RECOMENDADOS...2068
PROCEDIMIENTOS DE RODAJE...2070
IDENTIFICACIÓN DE LOS CILINDROS...2070
ETIQUETAS INFORMATIVAS...2071
ESPECIFICACIONES...2072
02 MANTENIMIENTO PERIODICO...2074
CALENDARIO DE MANTENIMIENTO PERIÓDICO...2075
PROCEDIMIENTOS DE MANTENIMIENTO Y PUESTA A PUNTO...2077
COMPROBACIÓN DE LA PRESIÓN DE COMPRESIÓN...2105
COMPROBACIÓN DE LA PRESIÓN DEL ACEITE...2106
COMPROBACIÓN CON SDS...2107
03 MOTOR...2110
EXTRACCIÓN DE COMPONENTES DEL MOTOR CON EL MOTOR INSTALADO...2111
EXTRACCIÓN E INSTALACIÓN DEL MOTOR...2112
DESMONTAJE DEL MOTOR...2123
INSPECCIÓN Y MANTENIMIENTO DE LOS COMPONENTES DEL MOTOR...2135
MONTAJE DEL MOTOR...2179
04 DIAGNOSTICO DEL SISTEMA FI...2208
PRECAUCIONES DE MANTENIMIENTO...2210
CARACTERÍSTICAS TÉCNICAS DEL SISTEMA DE INYECCIÓN DE COMBUSTIBLE (FI)...2217
TERMINAL ECM...2222
FUNCIÓN DE AUTODIAGNOSIS...2224
FUNCIÓN DE SEGURO CONTRA FALLOS...2228
SOLUCIÓN DE AVERÍAS DEL SISTEMA FI...2230
SENSORES...2312
05 SISTEMA DE COMBUSTIBLE Y CUERPO DEL ACELERADOR...2315
SISTEMA DE DISTRIBUCIÓN DEL COMBUSTIBLE...2316
SISTEMA DE COMBUSTIBLE...2317
CUERPO DEL ACELERADOR...2327
06 SISTEMA DE ESCAPE...2342
SISTEMA DE ESCAPE...2343
EXCVA (ACTUADOR DE VÁLVULA DE CONTROL DE ESCAPE) Y EXCV (VÁLVULA DE CONTROL DE ESCAPE)...2345
07 SISTEMA DE REFRIGERACION Y LUBRICACION...2356
REFRIGERANTE DEL MOTOR...2357
CIRCUITO DE REFRIGERACIÓN...2358
RADIADOR Y MANGUERAS DE AGUA...2359
VENTILADOR DE REFRIGERACIÓN...2361
SENSOR ECT...2362
TERMOSTATO...2364
BOMBA DE AGUA...2366
SISTEMA DE LUBRICACIÓN...2372
08 CHASIS...2377
PIEZAS EXTERIORES...2379
RUEDA DELANTERA...2385
HORQUILLA DELANTERA...2393
AMORTIGUADOR DE DIRECCIÓN...2404
DIRECCIÓN...2406
MANILLARES...2412
RUEDA TRASERA...2416
AMORTIGUADOR TRASERO...2424
SUSPENSIÓN TRASERA...2430
FRENO DELANTERO...2440
FRENO TRASERO...2451
RUEDA Y NEUMÁTICO...2461
CADENA DE TRANSMISIÓN...2465
09 SISTEMA ELECTRICO...2469
PRECAUCIONES DE REPARACIÓN...2471
LOCALIZACIÓN DE COMPONENTES ELÉCTRICOS...2474
SISTEMA DE CARGA...2476
SISTEMAS DE ARRANQUE Y DE INTERCONEXIÓN DE PATA DE CABRA/ENCENDIDO...2480
SISTEMA DE ENCENDIDO...2488
PANEL DE INSTRUMENTOS COMBINADOS...2497
LUCES...2503
RELÉS...2505
BATERÍA...2508
10 INFORMACION DE SERVICIO...2511
SOLUCIÓN DE PROBLEMAS...2512
INSTALACIÓN DE CABLEADOS, CABLES Y LATIGUILLOS...2527
PAR DE APRIETE...2548
DATOS DE SERVICIO...2552
11 INFORMACION DE CONTROL DE LA EMISION...2561
SISTEMAS DE CONTROL DE LA EMISIÓN...2562
INSPECCIÓN DEL SISTEMA PAIR (SUMINISTRO DE AIRE) Y DEL SISTEMA DE CONTROL DE EMISIÓN...2566
INSTALACIÓN DE LA MANGUERA DEL SISTEMA PAIR (SUMINISTRO DE AIRE)...2568
INSPECCIÓN DEL SENSOR HO2 (Para E-02, 19)...2569
12 DIAGRAMA DE CABLEADO...2570
Suzuki GSX-R600K8 Service Manual '08 (EN)...2574
GSX-R600 SERVICE MANUAL...2574
FOREWORD...2575
TABLE OF CONTENTS...2576
Precautions...2578
Precautions...2579
Precautions...2579
Warning / Caution / Note...2579
General Precautions...2579
Precautions for Electrical Circuit Service...2580
General Information...2586
General Information...2587
General Description...2587
Symbols...2587
Abbreviations...2587
Vehicle Side View...2588
Vehicle Identification Number...2589
Fuel and Oil Recommendation...2589
Engine Coolant Recommendation...2590
BREAK-IN Procedures...2590
Cylinder Identification...2590
Country and Area Codes...2591
Wire Color Symbols...2591
Warning, Caution and Information Labels Location...2592
Component Location...2593
Electrical Components Location...2593
Specifications...2595
Specifications...2595
Special Tools and Equipment...2597
Special Tool...2597
Maintenance and Lubrication...2601
Precautions...2601
Precautions for Maintenance...2601
General Description...2601
Recommended Fluids and Lubricants...2601
Scheduled Maintenance...2601
Periodic Maintenance Schedule Chart...2601
Lubrication Points...2602
Repair Instructions...2603
Air Cleaner Element Replacement...2603
Air Cleaner Element Inspection...2603
Exhaust Pipe Bolt and Muffler Bolt Inspection...2603
Exhaust Control Valve Inspection...2604
Valve Clearance Inspection and Adjustment...2604
Spark Plug Replacement...2609
Spark Plug Inspection and Cleaning...2609
Fuel Line Inspection...2610
Evaporative Emission Control System Inspection (E-33 only)...2610
Engine Oil and Filter Replacement...2610
Throttle Cable Play Inspection and Adjustment...2612
PAIR System Inspection...2612
Throttle Valve Synchronization...2612
Cooling System Inspection...2612
Clutch Cable Play Inspection and Adjustment...2614
Drive Chain Inspection and Adjustment...2615
Drive Chain Cleaning and Lubricating...2616
Brake System Inspection...2617
Tire Inspection...2619
Steering System Inspection...2619
Front Fork Inspection...2620
Rear Suspension Inspection...2620
Chassis Bolt and Nut Inspection...2620
Compression Pressure Check...2622
Oil Pressure Check...2622
SDS Check...2622
Specifications...2622
Tightening Torque Specifications...2622
Special Tools and Equipment...2623
Recommended Service Material...2623
Special Tool...2623
Service Data...2624
Specifications...2624
Service Data...2624
Tightening Torque List...2632
Engine...2636
Precautions...2641
Precautions...2641
Precautions for Engine...2641
Engine General Information and Diagnosis...2642
General Description...2642
Injection Timing Description...2642
Self-Diagnosis Function...2644
Schematic and Routing Diagram...2645
FI System Wiring Diagram...2645
Terminal Alignment of ECM Coupler...2647
Component Location...2648
FI System Parts Location...2648
Diagnostic Information and Procedures...2650
Engine Symptom Diagnosis...2650
Self-Diagnostic Procedures...2654
Use of SDS Diagnosis Reset Procedures...2656
Show Data When Trouble (Displaying Data at the Time of DTC)...2657
SDS Check...2658
DTC Table...2662
Fail-Safe Function Table...2664
FI System Troubleshooting...2665
Malfunction Code and Defective Condition Table...2667
DTC “C11” (P0340): CMP Sensor Circuit Malfunction...2671
DTC “C12” (P0335): CKP Sensor Circuit Malfunction...2674
DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction...2677
DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction...2686
DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction...2693
DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction...2698
DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction...2703
DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction...2712
DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction...2719
DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction...2719
DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction...2723
DTC “C31” (P0705): GP Switch Circuit Malfunction...2730
DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction...2732
DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction...2735
DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction...2738
DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction...2742
DTC “C41” (P2505): ECM Power Input Signal Malfunction...2745
DTC “C42” (P1650): IG Switch Circuit Malfunction...2747
DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction...2747
DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction...2753
DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction...2767
DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction...2770
DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)...2773
DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction...2776
DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction...2779
Specifications...2783
Service Data...2783
Special Tools and Equipment...2784
Special Tool...2784
Emission Control Devices...2786
Precautions...2786
Precautions for Emission Control Devices...2786
General Description...2786
Fuel Injection System Description...2786
Crankcase Emission Control System Description...2787
Exhaust Emission Control System Description...2788
Noise Emission Control System Description...2789
Evaporative Emission Control System Diagram (Only for E-33)...2789
Schematic and Routing Diagram...2790
PAIR System Hose Routing Diagram...2790
EVAP Canister Hose Routing Diagram (Only for E-33)...2791
Repair Instructions...2792
Heated Oxygen Sensor (HO2S) Removal and Installation...2792
Heated Oxygen Sensor (HO2S) Inspection...2792
PAIR Reed Valve Removal and Installation...2792
PAIR Control Solenoid Valve Removal and Installation...2794
PAIR System Inspection...2794
Crankcase Breather (PCV) Hose Inspection...2795
Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation...2796
Crankcase Breather (PCV) Cover Inspection...2797
Crankcase Breather (PCV) Reed Valve Inspection...2797
Evaporative Emission Control System Removal and Installation (Only for E-33)...2797
Evaporative Emission Control System Inspection (Only for E-33)...2800
Specifications...2802
Service Data...2802
Tightening Torque Specifications...2802
Special Tools and Equipment...2802
Special Tool...2802
Engine Electrical Devices...2803
Precautions...2803
Precautions for Engine Electrical Device...2803
Component Location...2803
Engine Electrical Components Location...2803
Diagnostic Information and Procedures...2803
Engine Symptom Diagnosis...2803
Repair Instructions...2803
ECM Removal and Installation...2803
CMP Sensor Inspection...2804
CMP Sensor Removal and Installation...2804
CKP Sensor Inspection...2805
CKP Sensor Removal and Installation...2805
IAP Sensor Inspection...2805
IAP Sensor Removal and Installation...2805
TP Sensor Inspection...2805
TP Sensor Removal and Installation...2805
TP Sensor Adjustment...2806
ECT Sensor Removal and Installation...2806
ECT Sensor Inspection...2807
IAT Sensor Removal and Installation...2807
IAT Sensor Inspection...2808
AP Sensor Inspection...2808
AP Sensor Removal and Installation...2808
TO Sensor Inspection...2808
TO Sensor Removal and Installation...2808
STP Sensor Inspection...2809
STP Sensor Adjustment...2809
STP Sensor Removal and Installation...2810
STV Actuator Inspection...2810
STV Actuator Removal and Installation...2810
ISC Valve Inspection...2810
ISC Valve Removal and Installation...2810
ISC Valve Preset and Opening Initialization...2811
HO2 Sensor Inspection...2811
HO2 Sensor Removal and Installation...2811
GP Switch Inspection...2811
GP Switch Removal and Installation...2811
Specifications...2812
Service Data...2812
Tightening Torque Specifications...2812
Special Tools and Equipment...2813
Special Tool...2813
Engine Mechanical...2814
Schematic and Routing Diagram...2814
Camshaft and Sprocket Assembly Diagram...2814
Throttle Cable Routing Diagram...2815
Diagnostic Information and Procedures...2816
Engine Mechanical Symptom Diagnosis...2816
Compression Pressure Check...2816
Repair Instructions...2817
Engine Components Removable with the Engine in Place...2817
Air Cleaner Element Removal and Installation...2819
Air Cleaner Box Removal and Installation...2820
Air Cleaner Element Inspection and Cleaning...2820
Throttle Cable Removal and Installation...2820
Throttle Cable Inspection...2820
Throttle Cable Play Inspection and Adjustment...2820
Throttle Body Components...2821
Throttle Body Construction...2822
Throttle Body Removal and Installation...2823
Throttle Body Disassembly and Assembly...2824
Throttle Body Inspection and Cleaning...2828
ISC Valve Visual Inspection...2829
Throttle Valve Synchronization...2829
ISC Valve Reset...2831
TP Reset...2831
Engine Assembly Removal...2832
Engine Assembly Installation...2836
Engine Top Side Disassembly...2838
Engine Top Side Assembly...2840
Camshaft Inspection...2847
Camshaft Sprocket...2849
Cam Chain Tension Adjuster Inspection...2849
Cam Chain Guide / Cam Chain Tensioner Removal and Installation...2850
Cam Chain Guide Inspection...2850
Cam Chain Tensioner Inspection...2850
Cylinder Head Disassembly and Assembly...2851
Cylinder Head Related Parts Inspection...2855
Valve Guide Replacement...2858
Valve Seat Repair...2860
Engine Bottom Side Disassembly...2860
Engine Bottom Side Assembly...2867
Cylinder Inspection...2882
Piston Ring Removal and Installation...2882
Piston and Piston Ring Inspection...2884
Conrod Crank Pin Bearing Removal and Installation...2886
Conrod and Crankshaft Inspection...2886
Conrod Crank Pin Bearing Inspection and Selection...2887
Crankshaft Journal Bearing Inspection and Selection...2889
Crankshaft Thrust Clearance Inspection and Selection...2892
Specifications...2894
Service Data...2894
Tightening Torque Specifications...2896
Special Tools and Equipment...2897
Recommended Service Material...2897
Special Tool...2897
Engine Lubrication System...2900
Precautions...2900
Precautions for Engine Oil...2900
Schematic and Routing Diagram...2901
Engine Lubrication System Chart Diagram...2901
Engine Lubrication Circuit Diagram...2902
Diagnostic Information and Procedures...2904
Engine Lubrication Symptom Diagnosis...2904
Oil Pressure Check...2904
Repair Instructions...2905
Engine Oil and Filter Replacement...2905
Engine Oil Level Inspection...2905
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation...2905
Oil Pressure Regulator / Oil Strainer Inspection...2906
Oil Cooler / Oil Cooler Hose Inspection...2907
Oil Cooler Removal and Installation...2907
Oil Pressure Switch Removal and Installation...2908
Oil Pressure Switch Inspection...2908
Oil Jet / Oil Gallery Jet Removal and Installation...2908
Oil Jet / Oil Gallery Jet Inspection...2910
Oil Pump Removal and Installation...2911
Oil Pump Inspection...2912
Oil Pump Drive Gear Removal and Installation...2912
Specifications...2913
Service Data...2913
Tightening Torque Specifications...2914
Special Tools and Equipment...2914
Recommended Service Material...2914
Special Tool...2914
Engine Cooling System...2915
Precautions...2915
Precautions for Engine Cooling System...2915
Precautions for Engine Coolant...2915
General Description...2915
Engine Coolant Description...2915
Schematic and Routing Diagram...2916
Cooling Circuit Diagram...2916
Water Hose Routing Diagram...2917
Diagnostic Information and Procedures...2918
Engine Cooling Symptom Diagnosis...2918
Repair Instructions...2918
Cooling Circuit Inspection...2918
Radiator Cap Inspection...2919
Radiator Inspection and Cleaning...2919
Radiator / Cooling Fan Motor Removal and Installation...2919
Water Hose Inspection...2920
Water Hose Removal and Installation...2921
Radiator Reservoir Tank Inspection...2921
Radiator Reservoir Tank Removal and Installation...2922
Cooling Fan Inspection...2922
Cooling Fan Relay Inspection...2922
ECT Sensor Removal and Installation...2923
ECT Sensor Inspection...2923
Thermostat Removal and Installation...2923
Thermostat Inspection...2924
Water Pump Components...2925
Water Pump Construction...2926
Water Pump Removal and Installation...2926
Water Pump Disassembly and Assembly...2927
Water Pump Related Parts Inspection...2930
Specifications...2932
Service Data...2932
Tightening Torque Specifications...2932
Special Tools and Equipment...2933
Recommended Service Material...2933
Special Tool...2933
Fuel System...2934
Precautions...2934
Precautions for Fuel System...2934
General Description...2935
Fuel Injection System Description...2935
Schematic and Routing Diagram...2936
Fuel Tank Drain Hose and Breather Hose Routing Diagram...2936
Diagnostic Information and Procedures...2937
Fuel System Diagnosis...2937
Repair Instructions...2938
Fuel Pressure Inspection...2938
Fuel Pump Inspection...2938
Fuel Discharge Amount Inspection...2939
Fuel Pump Relay Inspection...2940
Fuel Hose Inspection...2940
Fuel Level Gauge Inspection...2940
Fuel Tank Construction...2941
Fuel Tank Removal and Installation...2942
Fuel Pump Components...2943
Fuel Pump Disassembly and Assembly...2944
Fuel Mesh Filter Inspection and Cleaning...2946
Fuel Injector / Fuel Delivery Pipe / T-joint Removal and Installation...2946
Fuel Injector Inspection and Cleaning...2946
Specifications...2947
Service Data...2947
Tightening Torque Specifications...2947
Special Tools and Equipment...2948
Recommended Service Material...2948
Special Tool...2948
Ignition System...2949
General Description...2949
Immobilizer Description (For E-02, 19, 24)...2949
Drive Mode Selector Description...2950
Schematic and Routing Diagram...2951
Ignition System Diagram...2951
Ignition System Components Location...2951
Diagnostic Information and Procedures...2952
Ignition System Symptom Diagnosis...2952
No Spark or Poor Spark...2953
Repair Instructions...2954
Ignition Coil / Plug Cap and Spark Plug Removal and Installation...2954
Spark Plug Inspection and Cleaning...2955
Ignition Coil / Plug Cap Inspection...2955
CKP Sensor Inspection...2957
CKP Sensor Removal and Installation...2958
Engine Stop Switch Inspection...2958
Ignition Switch Inspection...2958
Ignition Switch Removal and Installation...2959
Drive Mode Selector Inspection...2960
Specifications...2961
Service Data...2961
Tightening Torque Specifications...2961
Special Tools and Equipment...2962
Recommended Service Material...2962
Special Tool...2962
Starting System...2963
Schematic and Routing Diagram...2963
Starting System Diagram...2963
Component Location...2963
Starting System Components Location...2963
Diagnostic Information and Procedures...2963
Starting System Symptom Diagnosis...2963
Starter Motor Will Not Run...2964
Starter Motor Runs But Does Not Crank The Engine...2964
Repair Instructions...2965
Starter Motor Components...2965
Starter Motor Removal and Installation...2966
Starter Motor Disassembly and Assembly...2966
Starter Motor Inspection...2967
Starter Relay Removal and Installation...2968
Starter Relay Inspection...2969
Turn Signal / Side-stand Relay Removal and Installation...2969
Side-stand / Ignition Interlock System Parts Inspection...2970
Starter Clutch Removal and Installation...2972
Starter Clutch Inspection...2974
Starter Button Inspection...2975
Specifications...2976
Service Data...2976
Tightening Torque Specifications...2976
Special Tools and Equipment...2977
Recommended Service Material...2977
Special Tool...2977
Charging System...2978
Schematic and Routing Diagram...2978
Charging System Diagram...2978
Component Location...2978
Charging System Components Location...2978
Diagnostic Information and Procedures...2978
Charging System Symptom Diagnosis...2978
Battery Runs Down Quickly...2979
Repair Instructions...2980
Battery Current Leakage Inspection...2980
Regulated Voltage Inspection...2980
Generator Inspection...2980
Generator Removal and Installation...2981
Regulator / Rectifier Construction...2985
Regulator / Rectifier Removal and Installation...2986
Regulator / Rectifier Inspection...2987
Battery Components...2988
Battery Charging...2988
Battery Removal and Installation...2990
Battery Visual Inspection...2991
Specifications...2991
Service Data...2991
Tightening Torque Specifications...2991
Special Tools and Equipment...2992
Recommended Service Material...2992
Special Tool...2992
Exhaust System...2993
Precautions...2993
Precautions for Exhaust System...2993
General Description...2993
Exhaust Control System Description...2993
Exhaust Control System Operation...2994
Repair Instructions...2996
Exhaust Control System Construction...2996
Exhaust System Components...2997
EXCV Cable Removal and Installation...2998
EXCVA Removal and Installation...2999
EXCVA Inspection...3001
EXCVA Pulley Inspection...3001
EXCVA Adjustment...3001
Exhaust Pipe / Muffler Removal and Installation...3003
Exhaust System Inspection...3006
Specifications...3007
Tightening Torque Specifications...3007
Special Tools and Equipment...3007
Recommended Service Material...3007
Special Tool...3007
Suspension...3008
Precautions...3009
Precautions...3009
Precautions for Suspension...3009
Suspension General Diagnosis...3010
Diagnostic Information and Procedures...3010
Suspension and Wheel Symptom Diagnosis...3010
Front Suspension...3011
Repair Instructions...3011
Front Fork Components...3011
Front Fork Removal and Installation...3012
Front Suspension Adjustment...3014
Front Fork Disassembly and Assembly...3014
Front Fork Parts Inspection...3021
Specifications...3022
Service Data...3022
Tightening Torque Specifications...3022
Special Tools and Equipment...3023
Recommended Service Material...3023
Special Tool...3023
Rear Suspension...3024
Repair Instructions...3024
Rear Suspension Components...3024
Rear Suspension Assembly Construction...3025
Rear Shock Absorber Removal and Installation...3026
Rear Suspension Inspection...3027
Rear Shock Absorber Inspection...3027
Rear Suspension Adjustment...3027
Rear Shock Absorber Disposal...3028
Cushion Lever Removal and Installation...3029
Cushion Lever Inspection...3029
Cushion Lever Bearing Removal and Installation...3030
Cushion Rod Removal and Installation...3031
Cushion Rod Inspection...3031
Cushion Rod Bearing Removal and Installation...3032
Swingarm Removal and Installation...3033
Swingarm Related Parts Inspection...3035
Swingarm Bearing Removal and Installation...3036
Specifications...3038
Service Data...3038
Tightening Torque Specifications...3038
Special Tools and Equipment...3039
Recommended Service Material...3039
Special Tool...3039
Wheels and Tires...3040
Precautions...3040
Precautions for Wheel and Tire...3040
Repair Instructions...3041
Front Wheel Components...3041
Front Wheel Assembly Construction...3042
Front Wheel Assembly Removal and Installation...3043
Front Wheel Related Parts Inspection...3045
Front Wheel Dust Seal / Bearing Removal and Installation...3046
Rear Wheel Components...3048
Rear Wheel Assembly Construction...3049
Rear Wheel Assembly Removal and Installation...3050
Rear Wheel Related Parts Inspection...3050
Rear Wheel Dust Seal / Bearing Removal and Installation...3052
Tire Removal and Installation...3054
Wheel / Tire / Air Valve Inspection and Cleaning...3055
Air Valve Removal and Installation...3056
Wheel Balance Check and Adjustment...3057
Specifications...3058
Service Data...3058
Tightening Torque Specifications...3058
Special Tools and Equipment...3059
Recommended Service Material...3059
Special Tool...3059
Driveline / Axle...3060
Precautions...3061
Precautions...3061
Precautions for Driveline / Axle...3061
Drive Chain / Drive Train / Drive Shaft...3062
Diagnostic Information and Procedures...3062
Drive Chain and Sprocket Symptom Diagnosis...3062
Repair Instructions...3062
Drive Chain Related Components...3062
Engine Sprocket Removal and Installation...3063
Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation...3064
Drive Chain Related Parts Inspection...3065
Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation...3066
Drive Chain Replacement...3068
Specifications...3071
Service Data...3071
Tightening Torque Specifications...3071
Special Tools and Equipment...3072
Recommended Service Material...3072
Special Tool...3072
Brake...3074
Precautions...3075
Precautions...3075
Precautions for Brake System...3075
Brake Fluid Information...3075
Brake Control System and Diagnosis...3076
Schematic and Routing Diagram...3076
Front Brake Hose Routing Diagram...3076
Rear Brake Hose Routing Diagram...3077
Diagnostic Information and Procedures...3078
Brake Symptom Diagnosis...3078
Repair Instructions...3079
Brake Pedal Height Inspection and Adjustment...3079
Front Brake Light Switch Inspection...3079
Rear Brake Light Switch Inspection...3079
Rear Brake Light Switch Inspection and Adjustment...3079
Brake Fluid Level Check...3080
Brake Hose Inspection...3080
Air Bleeding from Brake Fluid Circuit...3080
Brake Fluid Replacement...3082
Front Brake Hose Removal and Installation...3084
Rear Brake Hose Removal and Installation...3084
Front Brake Master Cylinder Components...3085
Front Brake Master Cylinder Assembly Removal and Installation...3086
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...3087
Front Brake Master Cylinder Parts Inspection...3089
Rear Brake Master Cylinder Components...3090
Rear Brake Master Cylinder Assembly Removal and Installation...3091
Rear Brake Master Cylinder Disassembly and Assembly...3091
Rear Brake Master Cylinder Parts Inspection...3093
Rear Brake Pedal Construction...3093
Rear Brake Pedal Removal and Installation...3094
Specifications...3094
Service Data...3094
Tightening Torque Specifications...3094
Special Tools and Equipment...3095
Recommended Service Material...3095
Special Tool...3095
Front Brakes...3096
Repair Instructions...3096
Front Brake Components...3096
Front Brake Pad Inspection...3097
Front Brake Pad Replacement...3097
Front Brake Caliper Removal and Installation...3098
Front Brake Caliper Disassembly and Assembly...3099
Front Brake Caliper Parts Inspection...3101
Front Brake Disc Removal and Installation...3102
Front Brake Disc Inspection...3102
Specifications...3103
Service Data...3103
Tightening Torque Specifications...3103
Special Tools and Equipment...3104
Recommended Service Material...3104
Special Tool...3104
Rear Brakes...3105
Repair Instructions...3105
Rear Brake Components...3105
Rear Brake Pad Inspection...3106
Rear Brake Pad Replacement...3106
Rear Brake Caliper Removal and Installation...3107
Rear Brake Caliper Disassembly and Assembly...3108
Rear Brake Caliper Parts Inspection...3109
Rear Brake Disc Removal and Installation...3110
Rear Brake Disc Inspection...3111
Specifications...3111
Service Data...3111
Tightening Torque Specifications...3111
Special Tools and Equipment...3112
Recommended Service Material...3112
Special Tool...3112
Transmission / Transaxle...3114
Precautions...3115
Precautions...3115
Precautions for Transmission / Transaxle...3115
Manual Transmission...3116
Diagnostic Information and Procedures...3116
Manual Transmission Symptom Diagnosis...3116
Repair Instructions...3117
Transmission Components...3117
Transmission Removal...3118
Transmission Installation...3120
Transmission Construction...3124
Countershaft Gear / Driveshaft Gear Disassembly and Assembly...3124
Transmission Related Parts Inspection...3126
Gear Position (GP) Switch Inspection...3128
Gear Position (GP) Switch Removal and Installation...3128
Gearshift Lever Construction...3129
Gearshift Lever Removal and Installation...3129
Gearshift Lever Height Inspection and Adjustment...3129
Gearshift Shaft / Gearshift Cam Plate Components...3130
Gearshift Shaft Construction...3130
Gearshift Shaft / Gearshift Cam Plate Removal and Installation...3131
Gearshift Linkage Inspection...3133
Gearshift Shaft Oil Seal / Bearing Removal and Installation...3134
Specifications...3135
Service Data...3135
Tightening Torque Specifications...3135
Special Tools and Equipment...3136
Recommended Service Material...3136
Special Tool...3136
Clutch...3138
Precautions...3138
Precautions for Clutch System...3138
Schematic and Routing Diagram...3138
Clutch Cable Routing Diagram...3138
Diagnostic Information and Procedures...3138
Clutch System Symptom Diagnosis...3138
Repair Instructions...3139
Clutch Lever Position Switch Inspection...3139
Clutch Cable Inspection...3139
Clutch Cable Removal and Installation...3139
Clutch Control System Components...3140
Clutch Components...3141
Clutch Removal...3142
Clutch Installation...3144
Clutch Parts Inspection...3148
Clutch Lifter Pin Inspection and Adjustment...3150
Specifications...3151
Service Data...3151
Tightening Torque Specifications...3151
Special Tools and Equipment...3152
Recommended Service Material...3152
Special Tool...3152
Steering...3154
Precautions...3155
Precautions...3155
Precautions for Steering...3155
Steering General Diagnosis...3156
Diagnostic Information and Procedures...3156
Steering Symptom Diagnosis...3156
Steering / Handlebar...3157
Repair Instructions...3157
Handlebar Components...3157
Handlebar Removal and Installation...3158
Handlebars Inspection...3160
Steering Components...3161
Steering Damper Construction...3162
Steering / Steering Damper Removal and Installation...3162
Steering / Steering Damper Related Parts Inspection...3165
Steering System Inspection...3166
Steering Stem Bearing Removal and Installation...3166
Steering Tension Adjustment...3167
Specifications...3168
Tightening Torque Specifications...3168
Special Tools and Equipment...3169
Recommended Service Material...3169
Special Tool...3169
Body and Accessories...3170
Precautions...3172
Precautions...3172
Precautions for Electrical System...3172
Component Location...3172
Electrical Components Location...3172
Wiring Systems...3173
Schematic and Routing Diagram...3173
Wiring Diagram...3173
Wiring Harness Routing Diagram...3177
Specifications...3181
Service Data...3181
Tightening Torque Specifications...3181
Special Tools and Equipment...3181
Recommended Service Material...3181
Lighting Systems...3182
Repair Instructions...3182
Headlight Components...3182
Headlight Removal and Installation...3183
Headlight Bulb and Position Light Bulb Replacement...3183
Headlight Beam Adjustment...3185
Front Turn Signal Light Components...3185
Front Turn Signal Light Removal and Installation...3186
Front Turn Signal Light Bulb Replacement...3186
Rear Lighting System Construction...3187
Rear Combination Light Removal and Installation...3188
Rear Combination Light Replacement...3189
License Plate Light Components...3189
License Plate Light Removal and Installation...3189
License Plate Light Bulb Replacement...3190
Rear Turn Signal Light Components...3191
Rear Turn Signal Light Removal and Installation...3191
Rear Turn Signal Light Bulb Replacement...3192
Reflex Reflector Construction...3192
Headlight Relay Inspection...3193
Turn Signal / Side-Stand Relay Inspection...3193
Turn Signal / Side-Stand Relay Removal and Installation...3193
Hazard Switch Inspection...3193
Turn Signal Switch Inspection...3194
Passing Light Switch Inspection...3194
Dimmer Switch Inspection...3195
Specifications...3195
Service Data...3195
Tightening Torque Specifications...3195
Special Tools and Equipment...3196
Recommended Service Material...3196
Special Tool...3196
Combination Meter / Fuel Meter / Horn...3197
General Description...3197
Combination Meter System Description...3197
Repair Instructions...3198
Combination Meter Components...3198
Combination Meter Removal and Installation...3198
Combination Meter Disassembly and Assembly...3198
Combination Meter Inspection...3199
Engine Coolant Temperature Indicator Light Inspection...3199
ECT Sensor Removal and Installation...3200
Fuel Level Indicator Inspection...3201
Fuel Level Gauge Inspection...3201
Speedometer Inspection...3201
Speed Sensor Removal and Installation...3201
Speed Sensor Inspection...3202
Oil Pressure Indicator Inspection...3202
Oil Pressure Switch Removal and Installation...3203
Oil Pressure Switch Inspection...3203
Ignition Switch Inspection...3203
Ignition Switch Removal and Installation...3204
Horn Inspection...3204
Horn Removal and Installation...3204
Specifications...3205
Service Data...3205
Tightening Torque Specifications...3205
Special Tools and Equipment...3205
Special Tool...3205
Exterior Parts...3206
Repair Instructions...3206
Exterior Parts Construction...3206
Body Cowling Cushion Attachment...3207
Under Cowling Heat Shield / Cushion Attachment...3208
Rear Fender Construction...3209
Frame Cover Construction...3210
Frame Side Cover Cushion Attachment...3211
Fuel Tank Cover Cushion Attachment...3212
Rear View Mirror Construction...3213
Rear View Mirror Cushion Attachment...3214
Fastener Removal and Installation...3215
Exterior Parts Removal and Installation...3216
Specifications...3220
Tightening Torque Specifications...3220
Body Structure...3221
Repair Instructions...3221
Body Frame Construction...3221
Front Footrest Bracket Construction...3222
Side-stand Construction...3223
Pillion Footrest Construction...3223
Side-stand Removal and Installation...3224
Specifications...3224
Tightening Torque Specifications...3224
Special Tools and Equipment...3224
Recommended Service Material...3224
Suzuki GSX-R400, GSX-R600 Repair Service Manual 1997-2008
