Suzuki GSX-R400 GK71B GK71F 1984-1987 & GSX-R600 1997-2008 Workshop Repair Service Manual PDF - MSZKGSXR600OPMS.zip
The complete service and repair guide for the Suzuki GSX-R400 and GSX-R600, featuring full electrical wiring diagrams, delivers every technical detail you need to service, troubleshoot, fix, and rebuild these bikes the way professional technicians do.
Contained within this Suzuki GSX-R400 and GSX-R600 workshop service and repair manual are:
* 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