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GSF600Y 2000
Suzuki GSF600Y 2000 User Manual
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7-12
SER
VICING INFORMA
TION
WIRE HARNESS,
CABLE AND HOSE R
OUTING
WIRE HARNESS ROUTING
Rear turn signal (LH)
Clamp
Clamp
Clamp
Wiring har
ness
Clamp
Handle s
witch (LH and RH)
Clamp
Wiring har
ness
TPS
Carburetor heater
(E-02 only)
Clamp
Wiring har
ness
Rear turn signal (RH)
Clamp
Wiring har
ness
Rear turn signal (RH)
Clamp
Wiring har
ness
Clamp
Wiring har
ness
Clamp
Wiring har
ness
T
o rear tur
n
signal (LH)
T
o rear tur
n
signal (RH)
T
o CDI unit
Wiring har
ness
Clamp
Thermo switch
Clamp
Clamp
Gear position s
witch
Side-stand s
witch
Wiring har
ness
Ignition coil
Batter
y
Carburetor heater
(E-02 only)
Batter
y
Brak
e light switch
T
o engine ground
Wiring har
ness
279
281
Table of Contents
Foreword Group Index
2
Table of Contents
2
How to Use this Manual
3
General Information
6
Suzuki Gsf600Sy (2000-Model)
8
Serial Number Location
8
Fuel and Oil Recommendation
8
Fuel
8
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
Break-In Procedures
9
Cylinder Identification
9
Information Labels
10
Specifications
11
Country or Area Codes
13
General Precautions
6
Warning/Caution/Note
6
Periodic Maintenance
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Lubrication Points
16
Maintenance and Tune-Up Procedures
17
Valve Clearance
17
Engine
17
Spark Plugs
18
Exhaust Pipe Bolts and Muffler Bolts
20
Air Cleaner
20
Engine Oil and Oil Filter
22
Fuel Hose
23
Fuel Filter
24
Engine Idle Speed
24
Throttle Cable Play
24
Carburetor Synchronization
25
Evaporative Emission Control System (E-33 Only)
25
Pair (Air Supply) System
26
Clutch Cable Play
26
Drive Chain
27
Brakes
29
Tires
32
Steering
33
Front Fork
34
Rear Suspension
34
Chassis Bolts and Nuts
35
Compression Pressure Check
37
Oil Pressure Check
38
Engine
39
Engine Components Removable with Engine in Place
40
Engine Removal and Installation
41
Engine Removal
41
Engine Reinstallation
46
Engine Disassembly and Reassembly
50
Engine Reassembly
64
Engine Components Inspection and Service
87
Camshaft/Cylinder Head
87
Cam Chain Tensioner
89
Valve
91
Valve Guide
93
Valve Seat
94
Valve Spring
98
Cylinder
102
Piston Ring Groove Width
103
Piston Ring Thickness
103
Piston Ring End Gap
103
Piston Pin
104
Clutch
106
Starter Clutch Inspection
107
Gearshift Linkage Inspection
108
Transmission Inspection and Service
110
Conrod
119
Crankshaft
121
Crankshaft Thrust Clearance Adjustment
123
Crankshaft Runout
124
Engine Lubrication System
125
Oil Filter
130
Oil Pressure
130
Oil Jet
130
Cylinder Head Cover
134
Oil Pan
134
Pair (Air Supply) System
136
Fuel System
139
Fuel System
140
Fuel Tank
141
Removal
141
Remounting
141
Fuel Valve
142
Removal
143
Inspection and Cleaning
143
Remounting
143
Fuel Filter Removal
144
Inspection
144
Fuel Filter Remounting
144
Carburetor
145
Construction
145
Specifications
146
I.D. No. Location
147
Diaphragm and Piston Operation
148
Slow System
149
Main System
150
Starter (Enricher) System
151
Float System
151
Removal
152
Disassembly
153
Carburetor Cleaning
157
Carburetor Heater Inspection
157
Thermo-Switch Inspection
157
Carburetor Inspection
158
Reassembly
159
Remounting
160
Carburetor Synchronization
161
Chassis
165
Exterior Parts
166
Construction
166
Removal
167
Remounting
170
Front Wheel
171
Construction
171
Removal
173
Inspection and Disassembly
173
Reassembly
174
Remounting
175
Front Fork
176
Construction
176
Removal and Disassembly
177
Inspection
179
Reassembly and Remounting
180
Steering
184
Construction
184
Removal and Disassembly
184
Inspection and Disassembly
186
Reassembly and Remounting
186
Steering Tension Adjustment
189
Rear Wheel
190
Construction
190
Removal
192
Inspection and Disassembly
193
Reassembly
194
Remounting
195
Rear Suspension
196
Construction
196
Removal
198
Inspection and Disassembly
199
Reassembly
201
Rear Shock Absorber Disposal
202
Remounting
203
Final Inspection and Adjustment
204
Suspension Setting
204
Front Brake
205
Construction
205
Brake Pad Replacement
206
Brake Fluid Replacement
206
Brake Caliper Removal and Disassembly
207
Brake Caliper Inspection
208
Brake Caliper Reassembly and Remounting
209
Brake Disc Inspection
210
Brake Disc Removal and Remounting
210
Master Cylinder Removal and Disassembly
211
Master Cylinder Inspection
212
Master Cylinder Reassembly and Remounting
213
Rear Brake
215
Construction
215
Brake Pad Replacement
216
Brake Fluid Replacement
216
Brake Caliper Removal and Disassembly
217
Brake Caliper Inspection
218
Brake Caliper Reassembly and Remounting
218
Master Cylinder Removal and Disassembly
219
Master Cylinder Inspection
220
Master Cylinder Reassembly and Remounting
221
Tire and Wheel
222
Tire Removal
222
Inspection
222
Tire Tread Depth
222
Tire Installation
223
Electrical System
225
Cautions in Servicing
226
Connecting the Battery
227
Using the Multi Circuit Tester
228
Location of Electrical Components
229
Charging System
231
Description (Generator with IC Regulator)
231
Troubleshooting
232
Inspection
233
Generator
234
Removal and Disassembly
235
Inspection
237
Generator Reassembly and Remounting
240
Starter System and Side-Stand Ignition Interlock System
242
Starter System Description
242
Side-Stand/Ignition Interlock System Description
242
Troubleshooting
244
Starter Motor Removal and Disassembly
245
Starter Motor Inspection
245
Starter Motor Reassembly and Remounting
246
Starter Relay Inspection
247
Side-Stand/Ignition Interlock System Part Inspection
248
Ignition System (Digital Ignitor)
251
Description
251
Troubleshooting
252
Inspection
253
Combination Meter
257
Removal
257
Disassembly
257
Inspection
257
Lamps
261
Headlight
261
Brake Light/Taillight and License Plate Light
262
Turn Signal Lights
262
Relays
263
Starter Relay
263
Turn Signal/Side-Stand Relay
263
Switches
264
Battery
265
Specifications
265
Removal
265
Remounting
265
Initial Charging
266
Servicing
267
Recharging Operation
268
Servicing Information
269
Troubleshooting
270
Engine
270
Carburetor
274
Chassis
274
Brakes
275
Electrical
276
Battery
277
Wiring Diagram
278
Wire Harness, Cable and Hose Routing
280
Wire Harness Routing
280
Cable Routing
283
Pair (Air Supply) System Hose Routing
284
Front Brake Hose Routing
285
Rear Brake Hose Routing
286
Front Footrest Bracket Set-Up
287
Fuel Tank Set-Up
288
High-Tension Cord Routing
289
Muffler Mounting
289
Center Stand Springs
290
Cowling and Cowling Brace Set-Up
291
Frame Cover and Side Frame Cover Set-Up
292
Cowling Cushion and Tape
293
Front Fender Cushion
294
Seat Lock Cable Routing
294
Special Tools
297
Tightening Torque
300
Engine
300
Chassis
301
Tightening Torque Chart
302
Service Data
303
Gsf600Y (2000-Model)
312
Country and Area Codes
312
Specifications
313
Dimensions and Dry Mass
313
Combination Meter
315
Headlight
318
Bulb Replacement
318
Headlight Beam Adjustment
319
Wiring Diagram
320
Wire Harness Routing
321
Front Brake Hose Routing
323
Service Data
324
Gsf600Sk1/Gsf600Suk1
332
Gsf600K2/Gsf600Sk2
352
Service Data (Gsf600S)
354
Service Data (Gsf600)
363
Fuel Level Gauge
371
Fuel Level Meter
372
Wiring Diagram Gsf600S
373
Wiring Diagram Gsf600
375
Wire Harness Routing (Gsf600S)
376
Wire Harness Routing (Gsf600)
377
4
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Suzuki GSF600Y 2000 Specifications
General
Brand
Suzuki
Model
GSF600Y 2000
Category
Motorcycle
Language
English
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