Slow System
This system supplies fuel during engine operation when the throttle valve is closed or slightly opened. The fuel from the float chamber D is metered by the pilot jet where it mixes with air coming in through the pilot air jet This mixture, rich with fuel, then goes up through the pilot passage to the pilot screw . Part of the mixture is discharged into the main bore through bypass ports . The mixture is metered by the pilot screw and sprayed into the main bore through the pilot outlet port 7 .
Suzuki Super Grease A
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, make sure that it is completely seated in its groove and securely fitted. When reassembling the transmission, attention must be given to the locations and positions of washers and circlips. The cross sectional view shows the...
Specifications
Starter enricher plunger cable play Starter enricher plunger cable play E-02 UK E-03 USA E-19 European markets E-24 Australia E-28 Canada E-33 California USA E-02 UK E-03 USA E-19 European markets E-24 Australia E-28 Canada E-33 California USA Each carburetor has an l.D. number printed on its body.
Suzuki Moly Paste
Install the crankshaft assembly along with the cam chain into the upper crankcase. Insert the right-and left-thrust bearings with the oil grooves facing towards the crankshaft web. C 3-85 Clean the mating surfaces of the crankcases. Install the dowel pins in the upper crankcase. Apply the recommended bond to the mating surface of the lower crankcase as follows.
Fuel Valve
When the engine is not operating, the fuel valve is kept closed by the tension of the spring D, which closes the fuel passageway and stops the flow of fuel to the carburetors. When the engine has started, negative pressure vacuum is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor's main bore and the vacuum hose. This negative pressure vacuum is higher than the spring pressure which causes the diaphragm to force open the fuel valve and allow fuel...
Fuel System
3 5 5 6 7 7 8 DIAPHRAGM AND PISTON SLOW MAIN STARTER ENRICHER FLOAT CARBURETOR CARBURETOR HEATER THERMO-SWITCH CARBURETOR CARBURETOR
Carburetor Construction
Carburetor heater For E-02 Purge hose inlet pipe For E-33 Purge hose joint pipe For E-33 Jet needle stopper Jet needle Diaphragm Piston valve Needle jet Needle jet holder Main jet Pilot screw Pilot jet Needle valve assy Float Float pin Starter enricher plunger Gasket O-ring Float chamber Drain screw Vacuum inlet cap Vacuum hose for fuel valve Carburetor set shaft Upper and Lower TPS Throttle position sensor
Fuel And Oil Recommendation
1.Use only unleaded gasoline of at least 87 pump octane method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE Methyl Tertiary Butyl Ether is permitted. 4. Use of blended gasoline alcohol fuel is permitted, provided that the fuel contains not more than 10 ethanol. Gasoline alcohol fuel may contain up to 5 methanol if appropriate cosolvents and corrosion...
Conrodcrankshaft Inspection
Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. froh 09900-20602 Dial gauge 1 1000 mm 09900-22403 Small bore gauge 18-35 mm Service Limit 18.040 mm 0.7102 in Check the conrod big end side clearance using the thickness gauge. If the clearance exceeds the limit, measure the conrod big end width and crank pin width. If any of the measurements are out of specification, replace the...
Reed Vavle
Remove the PAIR valve cover. Inspect the reed valve for the carbon deposit. If the carbon deposit is found in the reed valve, replace the PAIR valve with a new one. Connect the vacuum pump gauge to the vacuum port of the PAIR valve as shown in the photograph. Apply negative pressure slowly to the PAIR valve and inspect the air flow. If air does not flow out within the specification, the PAIR valve is in normal condition. If the PAIR valve does not function within the specification, replace the...
Pair System Removal
Remove the fuel tank. ITT 4-3 Disconnect all of the PAIR valve hoses. Vacuum hose lt 2 Air cleaner hose D PAIR hose No. 1 PAIR hose No. 2 PAIR hose No. 3 PAIR hose No. 4
Removal
After draining the engine oil, the following components must be removed in the described order before removing the oil sump filter and the oil pressure regulator. Refer to the following pages for the details of each step.
Conrod big end oil clearance Service Limit 0080 mm 00031 in
If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table. Check the corresponding conrod I.D. code numbers 1 or 2 Check the corresponding crank pin O.D. code numbers 1, 2 or 3 37.000 - 37.008 mm 1.4567 - 1.4570 in 37.008-37.016 mm 1.4570- 1.4573 in 33.992 - 34.000 mm 1.3383- 1.3386 in 33.984 - 33.992 mm 1.3380- 1.3383 in 33.976 - 33.984 mm 1.3376 - 1.3380 in Ir55h 09900-20202 Micrometer 25 - 50 mm Ir55h 09900-20202 Micrometer 25 - 50 mm
EfflSI Crankshaft journal oil clearance Service Limit 008 mm 00031 in
If the width at the widest part of the compressed plastigauge exceeds the limit, replace the set of bearings with new ones. Refer to the selection table. Check the corresponding crankcase journal I.D. codes A or B , which are stamped on the rear of the upper crankcase. Check the corresponding crankshaft journal O.D. codes A, B or C which are stamped on the crankshaft. Bearing selection table Check the corresponding crankshaft journal O.D. codes A, B or C which are stamped on the crankshaft....
n 9900025140 SUZUKI MOLY PASTE
Place a cloth beneath the piston, and install the circlips NOTE Install the pistons with the arrow mark facing towards the exhaust side. Be sure to use new circlips. Install the dowel pins and the new cylinder gasket. Before installing the cylinder block, oil the big and small ends of each conrod and also the sliding surface of each piston. Install the gasket with the UP mark facing up as shown.
Piston Ring Installation
Install the oil ring first, then the 2nd ring and finally the 1st ring. NOTE The 1st and 2nd piston rings 2 differ in shape. piston rings should be installed with the First, install a spacer 3 into the oil ring groove and then install the two side rails The spacer and side rails do not have a designated top and bottom. They can be installed in any position.
Camshaftcylinder Head Inspection And Service
Identify the position of each removed part. Organize the parts in their respective groups i.e., intake, exhaust, 1 or 2 so that they can be installed in their original locations. If the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit. The camshaft runout should be checked. Also, check the cams and journals for wear or damage. The exhaust camshaft has the embossed letters EX and the intake camshaft has the embossed letters IN....
Valve lifter attachment 0991684511 Tweezers
Remove the valve spring retainer and the inner and outer valve springs . Remove the valve spring seat. Remove the valve from the combustion chamber side. Decarbonize the combustion chambers. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head. Support the valve using V-blocks, as shown, and check its runout using the dial gauge. If the...
[5 Signal generator rotor bolt 25 Nm 25 kgfm 180 Ibft
Connect the oil pressure switch lead wire. Pass the signal generator lead wire through the upper crank-case as shown. 5 Generator mounting bolt 25 N-m 2.5 kgf-m, 18.0 Ib-ft Apply SUZUKI SUPER GREASE A to the generator O-ring. 99000-25010 SUZUKI SUPER GREASE A 5 Starter motor mounting bolt 6 N-m 0.6 kgf-m, 4.5 Ib-ft Apply SUZUKI SUPER GREASE A to the starter motor O-ring. Apply a small quantity of THREAD LOCK 1342 to the two bolts. tffl 99000-32050 THREAD LOCK 1342 99000-25010 SUZUKI SUPER...
Engine Removal And Installation Engine Removal
Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Remove the seat and side frame covers. CFS-S and -6 Remove the fuel tank. T7 4-3 Remove the fuel tank mounting bracket bolts . Remove the air cleaner box mounting bolts 2 . Remove the document tray D. First disconnect the battery lead wire, then disconnect the battery lead wire. Remove the oil drain plug and drain the engine oil. CT2-9 Disconnect all...
Suzuki Moly Paste 1
The exhaust camshaft has the embossed letters EX and the intake camshaft has the embossed letters IN. Also, the right end of each camshaft has a notch When the T mark on the signal generator rotor is aligned with the center of the pickup coil, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the crankshaft sprocket and the exhaust camshaft sprocket. The exhaust camshaft sprocket has an arrow marked 1 Turn the exhaust camshaft so that the arrow is aligned...
Valve guide reamer handle
Insert the reamer from the combustion chamber and always turn the reamer handle clockwise. Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. The ring-like dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the...
Engine Disassembly And Reassembly
Identify the position of each removed part. Organize the parts in their respective groups e.g., intake, exhaust so that they can be reinstalled in their original positions. Remove each PAIR valve pipe and hose. Remove the oil filter using the special tool. 1to5l1 09915-40610 Oil filter wrench Refer to page 2-10 for installation procedures. Remove the left and right oil hoses Ito5lI 09911-73730 5 mm T type hexagon wrench Remove the cylinder head cover 3 , Sj 09914-25811 6 mm T type hexagon...
t55l1 0990009004 Impact driver set tS 9900032050 THREAD LOCK 1342
Install the gearshift shaft . NOTE Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear. Install the washer and fix the gearshift shaft with the circlip. It55l1 09900-06107 Snap ring pliers Install the washer D, pin , oil pump driven gear and washer . Fix the oil pump driven gear with the circlip. froSh 09900-06107 Snap ring pliers Install the thrust washer onto the countershaft. NOTE The flat surface of the thrust washer should face out. Install...
Compression Pressure Check
The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service. 1 000 - 1 500 kPa 10 - 15 kgf cm2 142-213 psi Low compression pressure can indicate any of the following conditions Excessively worn cylinder walls Piston rings stuck in grooves Ruptured or...
Oil Pressure Check
Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Above 300 kPa 3.0 kgf cm2, 43 psi mn-ri _ , , _ , ,, , _ at 3 000 r min., oil temp, at 60 C 140 F Below 600 kPa 6.0 kgf cm2, 85 psi K v ' If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE Oil leakage from the oil passage Combination of the above items Engine oil viscosity is too high Combination of the above...
Information Labels
Information label For E-03, 28, 33 Vacuum hose routing label For E-33 SPECIFICATIONS DIMENSIONS AND DRY MASS 440 mm 56.7 in air-cooled, with SACS, DOHC, TSCC mm 1.917 in CVR32SS, four multi-plate type constant mesh 33 16 28 17 23 21 Rear type, gas oil damped, coil spring, spring preload 7-way adjustable, rebound damping force 4-way adjustable mm 3.9 in Ignition ignition Fully Transistorized Ignition B.T.D.C. at 1 200 r min E-28 13 B.T.D.C. at 1 500 r min Others V 28.8 kC 8 Ah 10HR A.C....
Maintenance Andtuneup Procedures
This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. Inspect initially at 1 000 km 600 miles, 1 month and every 12 000 km 7 500 miles, 12 months . Remove the seat and fuel tank. C7 4-3 Remove all of the spark plugs. Remove the cylinder head cover and signal generator cover. The valve clearance specification is different for both intake and exhaust valves. Valve clearance adjustment must be checked and adjusted 1 at the time of periodic...
Foreword
This manual contains an introductory description on the SUZUKI GSF600S and procedures for its inspection service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your...