Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Suzuki Gsx R 600 1997 – 2012 Service Repair Manual – PDF DOWNLOAD
Original price was: $42.95.$23.95Current price is: $23.95.
Suzuki Gsx R 600 1997 – 2012 Service Repair Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Suzuki Gsx R 600 1997 – 2012 Service Repair Manual Suzuki Gsx R 600 1997 – 2012 Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:1500+
DOWNLOADABLE:YES
FILE TYPE:PDF
SUZUKI GSX R 600 1997 – 2012 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki Gsx R 600 1997 – 2012 Service Repair Manual
FOREWORD:
This manual contains an introductory description on the SUZUKI GSX-R600 and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. 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 better 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 publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures.
- 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 motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
TABLE OF CONTENTS:
Suzuki Gsx R 600 1997 – 2012 Service Repair Manual
GSX-R600 SERVICE MANUAL.......................................................................................................... 1 FOREWORD..................................................................................................................... 2 TABLE OF CONTENTS............................................................................................................ 3 Precautions.................................................................................................................. 5 Precautions.............................................................................................................. 6 Precautions.......................................................................................................... 6 Warning / Caution / Note......................................................................................... 6 General Precautions.............................................................................................. 6 Precautions for Electrical Circuit Service....................................................................... 7 General Information.......................................................................................................... 13 General Information...................................................................................................... 14 General Description.................................................................................................. 14 Symbols.......................................................................................................... 14 Abbreviations.................................................................................................... 14 Vehicle Side View................................................................................................ 15 Vehicle Identification Number.................................................................................... 16 Fuel and Oil Recommendation...................................................................................... 16 Engine Coolant Recommendation.................................................................................... 17 BREAK-IN Procedures.............................................................................................. 17 Cylinder Identification.......................................................................................... 17 Country and Area Codes........................................................................................... 18 Wire Color Symbols............................................................................................... 18 Warning, Caution and Information Labels Location................................................................. 19 Component Location................................................................................................... 20 Electrical Components Location................................................................................... 20 Specifications....................................................................................................... 22 Specifications................................................................................................... 22 Special Tools and Equipment.......................................................................................... 24 Special Tool..................................................................................................... 24 Maintenance and Lubrication.............................................................................................. 28 Precautions.......................................................................................................... 28 Precautions for Maintenance...................................................................................... 28 General Description.................................................................................................. 28 Recommended Fluids and Lubricants................................................................................ 28 Scheduled Maintenance................................................................................................ 28 Periodic Maintenance Schedule Chart.............................................................................. 28 Lubrication Points............................................................................................... 29 Repair Instructions.................................................................................................. 30 Air Cleaner Element Replacement.................................................................................. 30 Air Cleaner Element Inspection................................................................................... 30 Exhaust Pipe Bolt and Muffler Bolt Inspection.................................................................... 30 Exhaust Control Valve Inspection................................................................................. 31 Valve Clearance Inspection and Adjustment........................................................................ 31 Spark Plug Replacement........................................................................................... 36 Spark Plug Inspection and Cleaning............................................................................... 36 Fuel Line Inspection............................................................................................. 37 Evaporative Emission Control System Inspection (E-33 only)....................................................... 37 Engine Oil and Filter Replacement................................................................................ 37 Throttle Cable Play Inspection and Adjustment.................................................................... 39 PAIR System Inspection........................................................................................... 39 Throttle Valve Synchronization................................................................................... 39 Cooling System Inspection........................................................................................ 39 Clutch Cable Play Inspection and Adjustment...................................................................... 41 Drive Chain Inspection and Adjustment............................................................................ 42 Drive Chain Cleaning and Lubricating............................................................................. 43 Brake System Inspection.......................................................................................... 44 Tire Inspection.................................................................................................. 46 Steering System Inspection....................................................................................... 46 Front Fork Inspection............................................................................................ 47 Rear Suspension Inspection....................................................................................... 47 Chassis Bolt and Nut Inspection.................................................................................. 47 Compression Pressure Check....................................................................................... 49 Oil Pressure Check............................................................................................... 49 SDS Check........................................................................................................ 49 Specifications....................................................................................................... 49 Tightening Torque Specifications................................................................................. 49 Special Tools and Equipment.......................................................................................... 50 Recommended Service Material..................................................................................... 50 Special Tool..................................................................................................... 50 Service Data............................................................................................................. 51 Specifications....................................................................................................... 51 Service Data..................................................................................................... 51 Tightening Torque List........................................................................................... 59 Engine....................................................................................................................... 63 Precautions.............................................................................................................. 68 Precautions.......................................................................................................... 68 Precautions for Engine........................................................................................... 68 Engine General Information and Diagnosis................................................................................. 69 General Description.................................................................................................. 69 Injection Timing Description..................................................................................... 69 Self-Diagnosis Function.......................................................................................... 71 Schematic and Routing Diagram........................................................................................ 72 FI System Wiring Diagram......................................................................................... 72 Terminal Alignment of ECM Coupler................................................................................ 74 Component Location................................................................................................... 75 FI System Parts Location......................................................................................... 75 Diagnostic Information and Procedures................................................................................ 77 Engine Symptom Diagnosis......................................................................................... 77 Self-Diagnostic Procedures....................................................................................... 81 Use of SDS Diagnosis Reset Procedures............................................................................ 83 Show Data When Trouble (Displaying Data at the Time of DTC)...................................................... 84 SDS Check........................................................................................................ 85 DTC Table........................................................................................................ 89 Fail-Safe Function Table......................................................................................... 91 FI System Troubleshooting........................................................................................ 92 Malfunction Code and Defective Condition Table................................................................... 94 DTC “C11” (P0340): CMP Sensor Circuit Malfunction................................................................ 98 DTC “C12” (P0335): CKP Sensor Circuit Malfunction................................................................101 DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction............................................................104 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction.............................................................113 DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction............................................................120 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction............................................................125 DTC “C22” (P1450-H/L): AP Sensor Circuit Malfunction.............................................................130 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction.............................................................139 DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction....................146 DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction..........................................146 DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction.............................150 DTC “C31” (P0705): GP Switch Circuit Malfunction.................................................................157 DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Primary Fuel Injector Circuit Malfunction......159 DTC “C36” (P1764), “C37” (P1765), “C38” (P1766) or “C39” (P1767): Secondary Fuel Injector Circuit Malfunction....162 DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction.................................................165 DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction..............................................................169 DTC “C41” (P2505): ECM Power Input Signal Malfunction............................................................172 DTC “C42” (P1650): IG Switch Circuit Malfunction.................................................................174 DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction...................................................174 DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction................................................180 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction...............................................194 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction.........................................................197 DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 only)......................200 DTC “C91” (P0500): Vehicle Speed Sensor Circuit Malfunction......................................................203 DTC “C93” (P1769): Steering Damper Solenoid Valve Circuit Malfunction............................................206 Specifications.......................................................................................................210 Service Data.....................................................................................................210 Special Tools and Equipment..........................................................................................211 Special Tool.....................................................................................................211 Emission Control Devices.................................................................................................213 Precautions..........................................................................................................213 Precautions for Emission Control Devices.........................................................................213 General Description..................................................................................................213 Fuel Injection System Description................................................................................213 Crankcase Emission Control System Description....................................................................214 Exhaust Emission Control System Description......................................................................215 Noise Emission Control System Description........................................................................216 Evaporative Emission Control System Diagram (Only for E-33)......................................................216 Schematic and Routing Diagram........................................................................................217 PAIR System Hose Routing Diagram.................................................................................217 EVAP Canister Hose Routing Diagram (Only for E-33)...............................................................218 Repair Instructions..................................................................................................219 Heated Oxygen Sensor (HO2S) Removal and Installation.............................................................219 Heated Oxygen Sensor (HO2S) Inspection...........................................................................219 PAIR Reed Valve Removal and Installation.........................................................................219 PAIR Control Solenoid Valve Removal and Installation.............................................................221 PAIR System Inspection...........................................................................................221 Crankcase Breather (PCV) Hose Inspection.........................................................................222 Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation......................................223 Crankcase Breather (PCV) Cover Inspection........................................................................224 Crankcase Breather (PCV) Reed Valve Inspection...................................................................224 Evaporative Emission Control System Removal and Installation (Only for E-33).....................................224 Evaporative Emission Control System Inspection (Only for E-33)...................................................227 Specifications.......................................................................................................229 Service Data.....................................................................................................229 Tightening Torque Specifications.................................................................................229 Special Tools and Equipment..........................................................................................229 Special Tool.....................................................................................................229 Engine Electrical Devices................................................................................................230 Precautions..........................................................................................................230 Precautions for Engine Electrical Device.........................................................................230 Component Location...................................................................................................230 Engine Electrical Components Location............................................................................230 Diagnostic Information and Procedures................................................................................230 Engine Symptom Diagnosis.........................................................................................230 Repair Instructions..................................................................................................230 ECM Removal and Installation.....................................................................................230 CMP Sensor Inspection............................................................................................231 CMP Sensor Removal and Installation..............................................................................231 CKP Sensor Inspection............................................................................................232 CKP Sensor Removal and Installation..............................................................................232 IAP Sensor Inspection............................................................................................232 IAP Sensor Removal and Installation..............................................................................232 TP Sensor Inspection.............................................................................................232 TP Sensor Removal and Installation...............................................................................232 TP Sensor Adjustment.............................................................................................233 ECT Sensor Removal and Installation..............................................................................233 ECT Sensor Inspection............................................................................................234 IAT Sensor Removal and Installation..............................................................................234 IAT Sensor Inspection............................................................................................235 AP Sensor Inspection.............................................................................................235 AP Sensor Removal and Installation...............................................................................235 TO Sensor Inspection.............................................................................................235 TO Sensor Removal and Installation...............................................................................235 STP Sensor Inspection............................................................................................236 STP Sensor Adjustment............................................................................................236 STP Sensor Removal and Installation..............................................................................237 STV Actuator Inspection..........................................................................................237 STV Actuator Removal and Installation............................................................................237 ISC Valve Inspection.............................................................................................237 ISC Valve Removal and Installation...............................................................................237 ISC Valve Preset and Opening Initialization......................................................................238 HO2 Sensor Inspection............................................................................................238 HO2 Sensor Removal and Installation..............................................................................238 GP Switch Inspection.............................................................................................238 GP Switch Removal and Installation...............................................................................238 Specifications.......................................................................................................239 Service Data.....................................................................................................239 Tightening Torque Specifications.................................................................................239 Special Tools and Equipment..........................................................................................240 Special Tool.....................................................................................................240 Engine Mechanical........................................................................................................241 Schematic and Routing Diagram........................................................................................241 Camshaft and Sprocket Assembly Diagram...........................................................................241 Throttle Cable Routing Diagram...................................................................................242 Diagnostic Information and Procedures................................................................................243 Engine Mechanical Symptom Diagnosis..............................................................................243 Compression Pressure Check.......................................................................................243 Repair Instructions..................................................................................................244 Engine Components Removable with the Engine in Place.............................................................244 Air Cleaner Element Removal and Installation.....................................................................246 Air Cleaner Box Removal and Installation.........................................................................247 Air Cleaner Element Inspection and Cleaning......................................................................247 Throttle Cable Removal and Installation..........................................................................247 Throttle Cable Inspection........................................................................................247 Throttle Cable Play Inspection and Adjustment....................................................................247 Throttle Body Components.........................................................................................248 Throttle Body Construction.......................................................................................249 Throttle Body Removal and Installation...........................................................................250 Throttle Body Disassembly and Assembly...........................................................................251 Throttle Body Inspection and Cleaning............................................................................255 ISC Valve Visual Inspection......................................................................................256 Throttle Valve Synchronization...................................................................................256 ISC Valve Reset..................................................................................................258 TP Reset.........................................................................................................258 Engine Assembly Removal..........................................................................................259 Engine Assembly Installation.....................................................................................263 Engine Top Side Disassembly......................................................................................265 Engine Top Side Assembly.........................................................................................267 Camshaft Inspection..............................................................................................274 Camshaft Sprocket................................................................................................276 Cam Chain Tension Adjuster Inspection............................................................................276 Cam Chain Guide / Cam Chain Tensioner Removal and Installation...................................................277 Cam Chain Guide Inspection.......................................................................................277 Cam Chain Tensioner Inspection...................................................................................277 Cylinder Head Disassembly and Assembly...........................................................................278 Cylinder Head Related Parts Inspection...........................................................................282 Valve Guide Replacement..........................................................................................285 Valve Seat Repair................................................................................................287 Engine Bottom Side Disassembly...................................................................................287 Engine Bottom Side Assembly......................................................................................294 Cylinder Inspection..............................................................................................309 Piston Ring Removal and Installation.............................................................................309 Piston and Piston Ring Inspection................................................................................311 Conrod Crank Pin Bearing Removal and Installation................................................................313 Conrod and Crankshaft Inspection.................................................................................313 Conrod Crank Pin Bearing Inspection and Selection................................................................314 Crankshaft Journal Bearing Inspection and Selection..............................................................316 Crankshaft Thrust Clearance Inspection and Selection.............................................................319 Specifications.......................................................................................................321 Service Data.....................................................................................................321 Tightening Torque Specifications.................................................................................323 Special Tools and Equipment..........................................................................................324 Recommended Service Material.....................................................................................324 Special Tool.....................................................................................................324 Engine Lubrication System................................................................................................327 Precautions..........................................................................................................327 Precautions for Engine Oil.......................................................................................327 Schematic and Routing Diagram........................................................................................328 Engine Lubrication System Chart Diagram..........................................................................328 Engine Lubrication Circuit Diagram...............................................................................329 Diagnostic Information and Procedures................................................................................331 Engine Lubrication Symptom Diagnosis.............................................................................331 Oil Pressure Check...............................................................................................331 Repair Instructions..................................................................................................332 Engine Oil and Filter Replacement................................................................................332 Engine Oil Level Inspection......................................................................................332 Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation.........................................332 Oil Pressure Regulator / Oil Strainer Inspection.................................................................333 Oil Cooler / Oil Cooler Hose Inspection..........................................................................334 Oil Cooler Removal and Installation..............................................................................334 Oil Pressure Switch Removal and Installation.....................................................................335 Oil Pressure Switch Inspection...................................................................................335 Oil Jet / Oil Gallery Jet Removal and Installation...............................................................335 Oil Jet / Oil Gallery Jet Inspection.............................................................................337 Oil Pump Removal and Installation................................................................................338 Oil Pump Inspection..............................................................................................339 Oil Pump Drive Gear Removal and Installation.....................................................................339 Specifications.......................................................................................................340 Service Data.....................................................................................................340 Tightening Torque Specifications.................................................................................341 Special Tools and Equipment..........................................................................................341 Recommended Service Material.....................................................................................341 Special Tool.....................................................................................................341 Engine Cooling System....................................................................................................342 Precautions..........................................................................................................342 Precautions for Engine Cooling System............................................................................342 Precautions for Engine Coolant...................................................................................342 General Description..................................................................................................342 Engine Coolant Description.......................................................................................342 Schematic and Routing Diagram........................................................................................343 Cooling Circuit Diagram..........................................................................................343 Water Hose Routing Diagram.......................................................................................344 Diagnostic Information and Procedures................................................................................345 Engine Cooling Symptom Diagnosis.................................................................................345 Repair Instructions..................................................................................................345 Cooling Circuit Inspection.......................................................................................345 Radiator Cap Inspection..........................................................................................346 Radiator Inspection and Cleaning.................................................................................346 Radiator / Cooling Fan Motor Removal and Installation............................................................346 Water Hose Inspection............................................................................................347 Water Hose Removal and Installation..............................................................................348 Radiator Reservoir Tank Inspection...............................................................................348 Radiator Reservoir Tank Removal and Installation.................................................................349 Cooling Fan Inspection...........................................................................................349 Cooling Fan Relay Inspection.....................................................................................349 ECT Sensor Removal and Installation..............................................................................350 ECT Sensor Inspection............................................................................................350 Thermostat Removal and Installation..............................................................................350 Thermostat Inspection............................................................................................351 Water Pump Components............................................................................................352 Water Pump Construction..........................................................................................353 Water Pump Removal and Installation..............................................................................353 Water Pump Disassembly and Assembly..............................................................................354 Water Pump Related Parts Inspection..............................................................................357 Specifications.......................................................................................................359 Service Data.....................................................................................................359 Tightening Torque Specifications.................................................................................359 Special Tools and Equipment..........................................................................................360 Recommended Service Material.....................................................................................360 Special Tool.....................................................................................................360 Fuel System..............................................................................................................361 Precautions..........................................................................................................361 Precautions for Fuel System......................................................................................361 General Description..................................................................................................362 Fuel Injection System Description................................................................................362 Schematic and Routing Diagram........................................................................................363 Fuel Tank Drain Hose and Breather Hose Routing Diagram...........................................................363 Diagnostic Information and Procedures................................................................................364 Fuel System Diagnosis............................................................................................364 Repair Instructions..................................................................................................365 Fuel Pressure Inspection.........................................................................................365 Fuel Pump Inspection.............................................................................................365 Fuel Discharge Amount Inspection.................................................................................366 Fuel Pump Relay Inspection.......................................................................................367 Fuel Hose Inspection.............................................................................................367 Fuel Level Gauge Inspection......................................................................................367 Fuel Tank Construction...........................................................................................368 Fuel Tank Removal and Installation...............................................................................369 Fuel Pump Components.............................................................................................370 Fuel Pump Disassembly and Assembly...............................................................................371 Fuel Mesh Filter Inspection and Cleaning.........................................................................373 Fuel Injector / Fuel Delivery Pipe / T-joint Removal and Installation............................................373 Fuel Injector Inspection and Cleaning............................................................................373 Specifications.......................................................................................................374 Service Data.....................................................................................................374 Tightening Torque Specifications.................................................................................374 Special Tools and Equipment..........................................................................................375 Recommended Service Material.....................................................................................375 Special Tool.....................................................................................................375 Ignition System..........................................................................................................376 General Description..................................................................................................376 Immobilizer Description (For E-02, 19, 24).......................................................................376 Drive Mode Selector Description..................................................................................377 Schematic and Routing Diagram........................................................................................378 Ignition System Diagram..........................................................................................378 Ignition System Components Location..............................................................................378 Diagnostic Information and Procedures................................................................................379 Ignition System Symptom Diagnosis................................................................................379 No Spark or Poor Spark...........................................................................................380 Repair Instructions..................................................................................................381 Ignition Coil / Plug Cap and Spark Plug Removal and Installation.................................................381 Spark Plug Inspection and Cleaning...............................................................................382 Ignition Coil / Plug Cap Inspection..............................................................................382 CKP Sensor Inspection............................................................................................384 CKP Sensor Removal and Installation..............................................................................385 Engine Stop Switch Inspection....................................................................................385 Ignition Switch Inspection.......................................................................................385 Ignition Switch Removal and Installation.........................................................................386 Drive Mode Selector Inspection...................................................................................387 Specifications.......................................................................................................388 Service Data.....................................................................................................388 Tightening Torque Specifications.................................................................................388 Special Tools and Equipment..........................................................................................389 Recommended Service Material.....................................................................................389 Special Tool.....................................................................................................389 Starting System..........................................................................................................390 Schematic and Routing Diagram........................................................................................390 Starting System Diagram..........................................................................................390 Component Location...................................................................................................390 Starting System Components Location..............................................................................390 Diagnostic Information and Procedures................................................................................390 Starting System Symptom Diagnosis................................................................................390 Starter Motor Will Not Run.......................................................................................391 Starter Motor Runs But Does Not Crank The Engine.................................................................391 Repair Instructions..................................................................................................392 Starter Motor Components.........................................................................................392 Starter Motor Removal and Installation...........................................................................393 Starter Motor Disassembly and Assembly...........................................................................393 Starter Motor Inspection.........................................................................................394 Starter Relay Removal and Installation...........................................................................395 Starter Relay Inspection.........................................................................................396 Turn Signal / Side-stand Relay Removal and Installation..........................................................396 Side-stand / Ignition Interlock System Parts Inspection..........................................................397 Starter Clutch Removal and Installation..........................................................................399 Starter Clutch Inspection........................................................................................401 Starter Button Inspection........................................................................................402 Specifications.......................................................................................................403 Service Data.....................................................................................................403 Tightening Torque Specifications.................................................................................403 Special Tools and Equipment..........................................................................................404 Recommended Service Material.....................................................................................404 Special Tool.....................................................................................................404 Charging System..........................................................................................................405 Schematic and Routing Diagram........................................................................................405 Charging System Diagram..........................................................................................405 Component Location...................................................................................................405 Charging System Components Location..............................................................................405 Diagnostic Information and Procedures................................................................................405 Charging System Symptom Diagnosis................................................................................405 Battery Runs Down Quickly........................................................................................406 Repair Instructions..................................................................................................407 Battery Current Leakage Inspection...............................................................................407 Regulated Voltage Inspection.....................................................................................407 Generator Inspection.............................................................................................407 Generator Removal and Installation...............................................................................408 Regulator / Rectifier Construction...............................................................................412 Regulator / Rectifier Removal and Installation...................................................................413 Regulator / Rectifier Inspection.................................................................................414 Battery Components...............................................................................................415 Battery Charging.................................................................................................415 Battery Removal and Installation.................................................................................417 Battery Visual Inspection........................................................................................418 Specifications.......................................................................................................418 Service Data.....................................................................................................418 Tightening Torque Specifications.................................................................................418 Special Tools and Equipment..........................................................................................419 Recommended Service Material.....................................................................................419 Special Tool.....................................................................................................419 Exhaust System...........................................................................................................420 Precautions..........................................................................................................420 Precautions for Exhaust System...................................................................................420 General Description..................................................................................................420 Exhaust Control System Description...............................................................................420 Exhaust Control System Operation.................................................................................421 Repair Instructions..................................................................................................423 Exhaust Control System Construction..............................................................................423 Exhaust System Components........................................................................................424 EXCV Cable Removal and Installation..............................................................................425 EXCVA Removal and Installation...................................................................................426 EXCVA Inspection.................................................................................................428 EXCVA Pulley Inspection..........................................................................................428 EXCVA Adjustment.................................................................................................428 Exhaust Pipe / Muffler Removal and Installation..................................................................430 Exhaust System Inspection........................................................................................433 Specifications.......................................................................................................434 Tightening Torque Specifications.................................................................................434 Special Tools and Equipment..........................................................................................434 Recommended Service Material.....................................................................................434 Special Tool.....................................................................................................434 Suspension...................................................................................................................435 Precautions..............................................................................................................436 Precautions..........................................................................................................436 Precautions for Suspension.......................................................................................436 Suspension General Diagnosis.............................................................................................437 Diagnostic Information and Procedures................................................................................437 Suspension and Wheel Symptom Diagnosis...........................................................................437 Front Suspension.........................................................................................................438 Repair Instructions..................................................................................................438 Front Fork Components............................................................................................438 Front Fork Removal and Installation..............................................................................439 Front Suspension Adjustment......................................................................................441 Front Fork Disassembly and Assembly..............................................................................441 Front Fork Parts Inspection......................................................................................448 Specifications.......................................................................................................449 Service Data.....................................................................................................449 Tightening Torque Specifications.................................................................................449 Special Tools and Equipment..........................................................................................450 Recommended Service Material.....................................................................................450 Special Tool.....................................................................................................450 Rear Suspension..........................................................................................................451 Repair Instructions..................................................................................................451 Rear Suspension Components.......................................................................................451 Rear Suspension Assembly Construction............................................................................452 Rear Shock Absorber Removal and Installation.....................................................................453 Rear Suspension Inspection.......................................................................................454 Rear Shock Absorber Inspection...................................................................................454 Rear Suspension Adjustment.......................................................................................454 Rear Shock Absorber Disposal.....................................................................................455 Cushion Lever Removal and Installation...........................................................................456 Cushion Lever Inspection.........................................................................................456 Cushion Lever Bearing Removal and Installation...................................................................457 Cushion Rod Removal and Installation.............................................................................458 Cushion Rod Inspection...........................................................................................458 Cushion Rod Bearing Removal and Installation.....................................................................459 Swingarm Removal and Installation................................................................................460 Swingarm Related Parts Inspection................................................................................462 Swingarm Bearing Removal and Installation........................................................................463 Specifications.......................................................................................................465 Service Data.....................................................................................................465 Tightening Torque Specifications.................................................................................465 Special Tools and Equipment..........................................................................................466 Recommended Service Material.....................................................................................466 Special Tool.....................................................................................................466 Wheels and Tires.........................................................................................................467 Precautions..........................................................................................................467 Precautions for Wheel and Tire...................................................................................467 Repair Instructions..................................................................................................468 Front Wheel Components...........................................................................................468 Front Wheel Assembly Construction................................................................................469 Front Wheel Assembly Removal and Installation....................................................................470 Front Wheel Related Parts Inspection.............................................................................472 Front Wheel Dust Seal / Bearing Removal and Installation.........................................................473 Rear Wheel Components............................................................................................475 Rear Wheel Assembly Construction.................................................................................476 Rear Wheel Assembly Removal and Installation.....................................................................477 Rear Wheel Related Parts Inspection..............................................................................477 Rear Wheel Dust Seal / Bearing Removal and Installation..........................................................479 Tire Removal and Installation....................................................................................481 Wheel / Tire / Air Valve Inspection and Cleaning.................................................................482 Air Valve Removal and Installation...............................................................................483 Wheel Balance Check and Adjustment...............................................................................484 Specifications.......................................................................................................485 Service Data.....................................................................................................485 Tightening Torque Specifications.................................................................................485 Special Tools and Equipment..........................................................................................486 Recommended Service Material.....................................................................................486 Special Tool.....................................................................................................486 Driveline / Axle.............................................................................................................487 Precautions..............................................................................................................488 Precautions..........................................................................................................488 Precautions for Driveline / Axle.................................................................................488 Drive Chain / Drive Train / Drive Shaft..................................................................................489 Diagnostic Information and Procedures................................................................................489 Drive Chain and Sprocket Symptom Diagnosis.......................................................................489 Repair Instructions..................................................................................................489 Drive Chain Related Components...................................................................................489 Engine Sprocket Removal and Installation.........................................................................490 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation.............................................491 Drive Chain Related Parts Inspection.............................................................................492 Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation..............................................493 Drive Chain Replacement..........................................................................................495 Specifications.......................................................................................................498 Service Data.....................................................................................................498 Tightening Torque Specifications.................................................................................498 Special Tools and Equipment..........................................................................................499 Recommended Service Material.....................................................................................499 Special Tool.....................................................................................................499 Brake........................................................................................................................501 Precautions..............................................................................................................502 Precautions..........................................................................................................502 Precautions for Brake System.....................................................................................502 Brake Fluid Information..........................................................................................502 Brake Control System and Diagnosis.......................................................................................503 Schematic and Routing Diagram........................................................................................503 Front Brake Hose Routing Diagram.................................................................................503 Rear Brake Hose Routing Diagram..................................................................................504 Diagnostic Information and Procedures................................................................................505 Brake Symptom Diagnosis..........................................................................................505 Repair Instructions..................................................................................................506 Brake Pedal Height Inspection and Adjustment.....................................................................506 Front Brake Light Switch Inspection..............................................................................506 Rear Brake Light Switch Inspection...............................................................................506 Rear Brake Light Switch Inspection and Adjustment................................................................506 Brake Fluid Level Check..........................................................................................507 Brake Hose Inspection............................................................................................507 Air Bleeding from Brake Fluid Circuit............................................................................507 Brake Fluid Replacement..........................................................................................509 Front Brake Hose Removal and Installation........................................................................511 Rear Brake Hose Removal and Installation.........................................................................511 Front Brake Master Cylinder Components...........................................................................512 Front Brake Master Cylinder Assembly Removal and Installation....................................................513 Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...............................................514 Front Brake Master Cylinder Parts Inspection.....................................................................516 Rear Brake Master Cylinder Components............................................................................517 Rear Brake Master Cylinder Assembly Removal and Installation.....................................................518 Rear Brake Master Cylinder Disassembly and Assembly..............................................................518 Rear Brake Master Cylinder Parts Inspection......................................................................520 Rear Brake Pedal Construction....................................................................................520 Rear Brake Pedal Removal and Installation........................................................................521 Specifications.......................................................................................................521 Service Data.....................................................................................................521 Tightening Torque Specifications.................................................................................521 Special Tools and Equipment..........................................................................................522 Recommended Service Material.....................................................................................522 Special Tool.....................................................................................................522 Front Brakes.............................................................................................................523 Repair Instructions..................................................................................................523 Front Brake Components...........................................................................................523 Front Brake Pad Inspection.......................................................................................524 Front Brake Pad Replacement......................................................................................524 Front Brake Caliper Removal and Installation.....................................................................525 Front Brake Caliper Disassembly and Assembly.....................................................................526 Front Brake Caliper Parts Inspection.............................................................................528 Front Brake Disc Removal and Installation........................................................................529 Front Brake Disc Inspection......................................................................................529 Specifications.......................................................................................................530 Service Data.....................................................................................................530 Tightening Torque Specifications.................................................................................530 Special Tools and Equipment..........................................................................................531 Recommended Service Material.....................................................................................531 Special Tool.....................................................................................................531 Rear Brakes..............................................................................................................532 Repair Instructions..................................................................................................532 Rear Brake Components............................................................................................532 Rear Brake Pad Inspection........................................................................................533 Rear Brake Pad Replacement.......................................................................................533 Rear Brake Caliper Removal and Installation......................................................................534 Rear Brake Caliper Disassembly and Assembly......................................................................535 Rear Brake Caliper Parts Inspection..............................................................................536 Rear Brake Disc Removal and Installation.........................................................................537 Rear Brake Disc Inspection.......................................................................................538 Specifications.......................................................................................................538 Service Data.....................................................................................................538 Tightening Torque Specifications.................................................................................538 Special Tools and Equipment..........................................................................................539 Recommended Service Material.....................................................................................539 Special Tool.....................................................................................................539 Transmission / Transaxle.....................................................................................................541 Precautions..............................................................................................................542 Precautions..........................................................................................................542 Precautions for Transmission / Transaxle.........................................................................542 Manual Transmission......................................................................................................543 Diagnostic Information and Procedures................................................................................543 Manual Transmission Symptom Diagnosis............................................................................543 Repair Instructions..................................................................................................544 Transmission Components..........................................................................................544 Transmission Removal.............................................................................................545 Transmission Installation........................................................................................547 Transmission Construction........................................................................................551 Countershaft Gear / Driveshaft Gear Disassembly and Assembly.....................................................551 Transmission Related Parts Inspection............................................................................553 Gear Position (GP) Switch Inspection.............................................................................555 Gear Position (GP) Switch Removal and Installation...............................................................555 Gearshift Lever Construction.....................................................................................556 Gearshift Lever Removal and Installation.........................................................................556 Gearshift Lever Height Inspection and Adjustment.................................................................556 Gearshift Shaft / Gearshift Cam Plate Components.................................................................557 Gearshift Shaft Construction.....................................................................................557 Gearshift Shaft / Gearshift Cam Plate Removal and Installation...................................................558 Gearshift Linkage Inspection.....................................................................................560 Gearshift Shaft Oil Seal / Bearing Removal and Installation......................................................561 Specifications.......................................................................................................562 Service Data.....................................................................................................562 Tightening Torque Specifications.................................................................................562 Special Tools and Equipment..........................................................................................563 Recommended Service Material.....................................................................................563 Special Tool.....................................................................................................563 Clutch...................................................................................................................565 Precautions..........................................................................................................565 Precautions for Clutch System....................................................................................565 Schematic and Routing Diagram........................................................................................565 Clutch Cable Routing Diagram.....................................................................................565 Diagnostic Information and Procedures................................................................................565 Clutch System Symptom Diagnosis..................................................................................565 Repair Instructions..................................................................................................566 Clutch Lever Position Switch Inspection..........................................................................566 Clutch Cable Inspection..........................................................................................566 Clutch Cable Removal and Installation............................................................................566 Clutch Control System Components.................................................................................567 Clutch Components................................................................................................568 Clutch Removal...................................................................................................569 Clutch Installation..............................................................................................571 Clutch Parts Inspection..........................................................................................575 Clutch Lifter Pin Inspection and Adjustment......................................................................577 Specifications.......................................................................................................578 Service Data.....................................................................................................578 Tightening Torque Specifications.................................................................................578 Special Tools and Equipment..........................................................................................579 Recommended Service Material.....................................................................................579 Special Tool.....................................................................................................579 Steering.....................................................................................................................581 Precautions..............................................................................................................582 Precautions..........................................................................................................582 Precautions for Steering.........................................................................................582 Steering General Diagnosis...............................................................................................583 Diagnostic Information and Procedures................................................................................583 Steering Symptom Diagnosis.......................................................................................583 Steering / Handlebar.....................................................................................................584 Repair Instructions..................................................................................................584 Handlebar Components.............................................................................................584 Handlebar Removal and Installation...............................................................................585 Handlebars Inspection............................................................................................587 Steering Components..............................................................................................588 Steering Damper Construction.....................................................................................589 Steering / Steering Damper Removal and Installation..............................................................589 Steering / Steering Damper Related Parts Inspection..............................................................592 Steering System Inspection.......................................................................................593 Steering Stem Bearing Removal and Installation...................................................................593 Steering Tension Adjustment......................................................................................594 Specifications.......................................................................................................595 Tightening Torque Specifications.................................................................................595 Special Tools and Equipment..........................................................................................596 Recommended Service Material.....................................................................................596 Special Tool.....................................................................................................596 Body and Accessories.........................................................................................................597 Precautions..............................................................................................................599 Precautions..........................................................................................................599 Precautions for Electrical System................................................................................599 Component Location...................................................................................................599 Electrical Components Location...................................................................................599 Wiring Systems...........................................................................................................600 Schematic and Routing Diagram........................................................................................600 Wiring Diagram...................................................................................................600 Wiring Harness Routing Diagram...................................................................................604 Specifications.......................................................................................................608 Service Data.....................................................................................................608 Tightening Torque Specifications.................................................................................608 Special Tools and Equipment..........................................................................................608 Recommended Service Material.....................................................................................608 Lighting Systems.........................................................................................................609 Repair Instructions..................................................................................................609 Headlight Components.............................................................................................609 Headlight Removal and Installation...............................................................................610 Headlight Bulb and Position Light Bulb Replacement...............................................................610 Headlight Beam Adjustment........................................................................................612 Front Turn Signal Light Components...............................................................................612 Front Turn Signal Light Removal and Installation.................................................................613 Front Turn Signal Light Bulb Replacement.........................................................................613 Rear Lighting System Construction................................................................................614 Rear Combination Light Removal and Installation..................................................................615 Rear Combination Light Replacement...............................................................................616 License Plate Light Components...................................................................................616 License Plate Light Removal and Installation.....................................................................616 License Plate Light Bulb Replacement.............................................................................617 Rear Turn Signal Light Components................................................................................618 Rear Turn Signal Light Removal and Installation..................................................................618 Rear Turn Signal Light Bulb Replacement..........................................................................619 Reflex Reflector Construction....................................................................................619 Headlight Relay Inspection.......................................................................................620 Turn Signal / Side-Stand Relay Inspection........................................................................620 Turn Signal / Side-Stand Relay Removal and Installation..........................................................620 Hazard Switch Inspection.........................................................................................620 Turn Signal Switch Inspection....................................................................................621 Passing Light Switch Inspection..................................................................................621 Dimmer Switch Inspection.........................................................................................622 Specifications.......................................................................................................622 Service Data.....................................................................................................622 Tightening Torque Specifications.................................................................................622 Special Tools and Equipment..........................................................................................623 Recommended Service Material.....................................................................................623 Special Tool.....................................................................................................623 Combination Meter / Fuel Meter / Horn....................................................................................624 General Description..................................................................................................624 Combination Meter System Description.............................................................................624 Repair Instructions..................................................................................................625 Combination Meter Components.....................................................................................625 Combination Meter Removal and Installation.......................................................................625 Combination Meter Disassembly and Assembly.......................................................................625 Combination Meter Inspection.....................................................................................626 Engine Coolant Temperature Indicator Light Inspection............................................................626 ECT Sensor Removal and Installation..............................................................................627 Fuel Level Indicator Inspection..................................................................................628 Fuel Level Gauge Inspection......................................................................................628 Speedometer Inspection...........................................................................................628 Speed Sensor Removal and Installation............................................................................628 Speed Sensor Inspection..........................................................................................629 Oil Pressure Indicator Inspection................................................................................629 Oil Pressure Switch Removal and Installation.....................................................................630 Oil Pressure Switch Inspection...................................................................................630 Ignition Switch Inspection.......................................................................................630 Ignition Switch Removal and Installation.........................................................................631 Horn Inspection..................................................................................................631 Horn Removal and Installation....................................................................................631 Specifications.......................................................................................................632 Service Data.....................................................................................................632 Tightening Torque Specifications.................................................................................632 Special Tools and Equipment..........................................................................................632 Special Tool.....................................................................................................632 Exterior Parts...........................................................................................................633 Repair Instructions..................................................................................................633 Exterior Parts Construction......................................................................................633 Body Cowling Cushion Attachment..................................................................................634 Under Cowling Heat Shield / Cushion Attachment...................................................................635 Rear Fender Construction.........................................................................................636 Frame Cover Construction.........................................................................................637 Frame Side Cover Cushion Attachment..............................................................................638 Fuel Tank Cover Cushion Attachment...............................................................................639 Rear View Mirror Construction....................................................................................640 Rear View Mirror Cushion Attachment..............................................................................641 Fastener Removal and Installation................................................................................642 Exterior Parts Removal and Installation..........................................................................643 Specifications.......................................................................................................647 Tightening Torque Specifications.................................................................................647 Body Structure...........................................................................................................648 Repair Instructions..................................................................................................648 Body Frame Construction..........................................................................................648 Front Footrest Bracket Construction..............................................................................649 Side-stand Construction..........................................................................................650 Pillion Footrest Construction....................................................................................650 Side-stand Removal and Installation..............................................................................651 Specifications.......................................................................................................651 Tightening Torque Specifications.................................................................................651 Special Tools and Equipment..........................................................................................651 Recommended Service Material.....................................................................................651
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
