Suzuki GSX-R600 2001-2005 : Service - Repair - Maintenance

Quick Reference Data ix General Information 1(28) Manual organization Warnings, cautions and notes Safety Serial numbers Fasteners Shop supplies Tools Measuring tools Electrical system fundamentals Service methods Storage Specifications Troubleshooting 29(16) Engine starting Engine will not start Engine performance Engine noises Engine lubrication Leakdown test Clutch Gearshift linkage Transmission Fuel system Electrical testing Electrical troubleshooting Steering and suspension Brake system Lubrication, Maintenance and Tune-Up 45(38) Cylinder numbering and firing order Maintenance intervals Tune-up Air filter replacement Compression test Ignition timing Valve clearance Spark plugs Engine oil and filter Engine oil pressure test Throttle cable adjustment Idle speed adjustment Fast idle speed adjustment Throttle valve synchronization Fuel line inspection Emission control system inspection Clutch adjustment Shift pedal height adjustment Cooling system Tires and wheels Front suspension Rear suspension Drive chain Brake system General lubrication Fastener inspection Specifications Engine Top End 83(31) Cylinder head cover Camshaft Cam chain tensioner Cam chain, chain guides and timing rotor Cylinder head Valve lifter and shims Valves and valve components Specifications Engine Lower End 114(48) Engine Starter idler cover Starter clutch and gears Alternator cover Flywheel Oil pump Oil cooler Oil pan and strainer Crankcase Crankshaft Connecting rod Piston and piston rings Engine break-in Specifications Clutch 162(13) Clutch cover Clutch Clutch release mechanism Clutch cable replacement Clutch lever assembly Specifications Transmission, Shift Mechanism and Engine Sprocket 175(20) Engine sprocket cover Engine sprocket Shift pedal/footrest External shift mechanism Internal shift mechanism Transmission Air, Fuel Injection, Emissions and Exhaust Systems 195(77) Fuel tank Fuel pump Fuel pump relay Air filter housing Throttle bodies Fuel injectors Throttle position (TP) sensor Secondary throttle position (STP) sensor Secondary throttle valve (STV) actuator Secondary throttle control (STC) unit Throttle cable replacement Fast idle cam Atmospheric pressure (AP) sensor Intake air pressure (IAP) sensor Intake air temperature (IAT) sensor Engine coolant temperature (ECT) sensor Camshaft position (CMP) sensor Tip-over (TO) sensor Exhaust system Evaporative emissions control system PAIR (air supply) system Diagnostic system Specifications Electrical System 272(38) Electrical component replacement Electrical connectors Battery Charging system Voltage regulator/rectifier Stator coil Ignition system Crankshaft position (CKP) sensor Engine control module (ECM) Ignition coil/plug cap Starting system Starter Starter relay Sidestand switch Gear position (GP) sensor Turn signal/sidestand relay Lighting system Horn Meter assembly Speed sensor Oil pressure switch Switches Fuses Wiring diagrams Specifications Cooling System 310(15) Hoses and clamps Cooling system Coolant reservoir Radiator Thermoswitch Radiator fan Thermostat Water jacket fitting Water pump Specifications Wheels, Tires and Drive Chain 325(21) Motorcycle stand Brake rotor protection Wheel inspection Front wheel Front hub Rear wheel Rear coupling and rear sprocket Rear hub Wheel balance Tires Drive chain Specifications Front Suspension and Steering 346(28) Handlebars Handlebar left grip replacement Steering head and stem Steering head bearing race replacement Steering stem race replacement Steering damper Front fork Specifications Rear Suspension 374(14) Shock absorber Suspension linkage Swing arm Suspension bearing Specifications Brakes 388(42) Brake service Brake bleeding Draining brake fluid Brake pad inspection Front brake caliper Front brake master cylinder Rear brake caliper Rear brake master cylinder Brake pedal/footpeg assembly Brake disc Brake hose replacement Specifications Body and Frame 430(15) Body panel fasteners Seat Passenger seat/tail cover Front engine cover Center panel Bracket cover Mirror Windshield Front fairing Fairing bracket Intake duct Side panel Tail piece Front fender Sidestand Specifications Index 445(6) Wiring Diagrams 451