Home > Motorcycles & ATV's > Suzuki Motorcyle & ATV >   Suzuki GSXR600 Repair Manual 2001-2005
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Details   Details This repair and service manual covers Suzuki GSXR600 including the GSXR600 2001-2005 US, California, Canada, UK, and European models, and the GSXR600 Alstare 2003 for the US, California, and Canadian market. Table of Contents QUICK REFERENCE DATA CHAPTER ONE: GENERAL INFORMATION Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications CHAPTER TWO: TROUBLESHOOTING 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 CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP 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 CHAPTER FOUR: ENGINE TOP END 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 CHAPTER FIVE: ENGINE LOWER END 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 CHAPTER SIX: CLUTCH Clutch cover | Clutch | Clutch release mechanism | Clutch cable replacement | Clutch lever assembly | Specifications CHAPTER SEVEN: TRANSMISSION, SHIFT MECHANISM and ENGINE SPROCKET Engine sprocket cover | Engine sprocket | Shift pedal | footrest | External shift mechanism | Internal shift mechanism | Transmission CHAPTER EIGHT: AIR, FUEL INJECTION, EMISSIONS and EXHAUST SYSTEMS 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 CHAPTER NINE: ELECTRICAL SYSTEM 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 CHAPTER TEN: COOLING SYSTEM Hoses and clamps | Cooling system | Coolant reservoir | Radiator | Thermoswitch | Radiator fan | Thermostat | Water jacket fitting | Water pump | Specifications CHAPTER ELEVEN: WHEELS, TIRES and DRIVE CHAIN 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 CHAPTER TWELVE: FRONT SUSPENSION and STEERING Handlebars | Handlebar left grip replacement | Steering head and stem | Steering head bearing race replacement | Steering stem race replacement | Steering damper | Front fork | Specifications CHAPTER THIRTEEN: REAR SUSPENSION Shock absorber | Suspension linkage | Swing arm | Suspension bearing | Specifications CHAPTER FOURTEEN: BRAKES 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 CHAPTER FIFTEEN: BODY and FRAME 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 COLOR WIRING DIAGRAMS Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild. PRODUCT DETAILS: Publisher: Clymer Manuals — 2007 Author: Clymer Staff Binding: Paperback — 7 x 10 inches Pages: 468 — Hundreds of b&w photos and illustrations ISBN: 9781599691169

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