Suzuki GSX-R600 2001 - 2005

Clymer Owners Service & Repair Manual

2001, 2002, 2003, 2004, 2005

by James Grooms

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Suzuki GSX-R600 2001 - 2005 - Front Cover

Front Cover

Front Cover

description

Suzuki GSX-R600 2001 - 2005 Clymer Owners Service & Repair Manual covers the following models:
● Suzuki GSX-R600, 2001-2005 (U.S., California, Canada, U.K., Europe)
● Suzuki GSX-R600 Alstare, 2003 (U.S., California, Canada)

Contents:
QUICK REFERENCE DATA

GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

TROUBLESHOOTING
Engine starting / Engine will not start / Engine performance / Engine noises / Engine lubrication / Leak down test / Clutch / Gearshift linkage / Transmission / Fuel system / Electrical testing / Electrical troubleshooting / Steering and suspension / Brake system / Specifications

LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance intervals schedule / Air filter / Compression test / Ignition timing / Valve clearance / Spark plugs / Engine oil and filter / Engine oil pressure test / Throttle cable / Idle speed / Fast idle speed / Throttle valve synchronization / Specifications

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

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

CLUTCH
Clutch release mechanism / Clutch cable / Clutch lever assembly / Specifications

TRANSMISSION, SHIFT MECHANISM AND ENGINE SPROCKET
Engine sprocket cover / Engine sprocket / Shift pedal / Footrest / External and internal shift mechanism / Transmission / Specifications

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

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

COOLING SYSTEM
Hoses and clamps / Cooling system / Coolant reservoir / Radiator / Thermoswitch / Radiator fan / Thermostat / Water jacket fitting / Water pump / Specifications

WHEELS, TYRES 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 / Tyres / Drive chain / Specifications

FRONT SUSPENSION AND STEERING
Handlebars / Steering head and stem / Steering head bearing race / Steering stem race / Steering damper / Front fork / Specifications

REAR SUSPENSION
Shock absorber / Suspension linkage / Swing arm / Suspension bearing / Specifications

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

BODY AND FRAME
Body panel fasteners / Seat / Passenger seat - tail section / Front engine cover / Center panel / Bracket cover / Mirror / Windshield / Front fairing / Fairing bracket / Intake duct / Side panel / Tail piece / Front fender / Sidestand / Specifications

COLOUR 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.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599691167 (1-599-69116-7)
  • ISBN-13: 9781599691169 (978-1-599-69116-9)
  • Format: Softcover, 468 pages
  • Date Published: 12-2006

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