Suzuki GSX-R600 2001-2005 Repair Manual by Clymer

Description

This Suzuki GSX-R600 2001 2002 2003 2004 2005 Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 2001-2005 Suzuki GSX-R600 models.
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

INDEX

WIRING DIAGRAMS