Мануал для suzuki katana

Brand: Suzuki
|
Category: Motorcycle
|
Size: 131.36 MB

• Group Index

  3

• Symbol

  4

• Component Parts and Work to be Done

  5

• General Information

  6

• Warning/Caution/Note

  7

• General Precautions

  7

• Suzuki GSX600FW (’98 Model) Right Side

  9

• Suzuki GSX600FW (’98 Model) Left Side

  9

• Serial Number Location

  9

• Fuel and Oil Recommendation

  9

• Engine Oil

  10

• Brake Fluid

  10

• Front Fork Oil

  10

• Break-In Procedures

  10

• Cylinder Identification

  11

• Information Labels

  12

• Specifications

  13

• Country and Area Codes

  15

• Periodic Maintenance

  16

• Periodic Maintenance Schedule

  17

• Periodic Maintenance Chart

  17

• Lubrication Points

  18

• Maintenance and Tune-Up Procedures

  19

• Valve Clearance

  19

• Spark Plugs

  20

• Carbon Deposits

  21

• Spark Plug Gap

  21

• Electrode’s Condition

  21

• Spark Plug Installation

  21

• Exhaust Pipe Bolts and Muffler Bolts and Nut

  22

• Air Cleaner

  22

• Engine Oil Replacement

  24

• Fuel Hose

  25

• Engine Oil Filter Replacement

  25

• Necessary Amount of Engine Oil

  25

• Fuel Filter

  26

• Engine Idle Speed

  26

• Throttle Cable Play

  26

• Carburetor Synchronization

  27

• Evaporative Emission Control System (E-33 Only)

  27

• Secondary Air Supply (Pair) System (E-33 Only)

  28

• Clutch Cable Play

  28

• Drive Chain

  29

• Drive Chain Adjusting

  30

• Drive Chain Cleaning and Lubricating

  30

• Brake Fluid Level

  31

• Brake Pads

  32

• Brake Pedal Height

  32

• Brake Light Switch

  33

• Air Bleeding the Brake Fluid Circuit

  33

• Tire Tread Condition

  35

• Tire Pressure

  35

• Steering

  36

• Front Fork

  36

• Rear Suspension

  36

• Chassis Bolts and Nuts

  37

• Compression Pressure Check

  39

• Compression Test Procedure

  39

• Oil Pressure Check

  40

• Oil Pressure Test Procedure

  40

• Low Oil Pressure

  40

• High Oil Pressure

  40

• Engine

  41

• Engine Components Removable with Engine in Place

  42

• Engine Removal

  43

• Engine Installation

  47

• Engine Disassembly

  51

• Engine Reassembly

  65

• Cylinder Block Stud Bolt Location

  77

• Camshaft/Cylinder Head

  88

• Camshaft Removal

  89

• Cylinder Head Removal

  90

• Camshaft/Cylinder Head Inspection and Service

  92

• Cam Wear

  93

• Camshaft Journal Wear

  93

• Camshaft Runout

  94

• Camshaft Sprockets

  94

• Cam Chain Tensioner

  95

• Cam Chain Guide

  95

• Cam Chain Tensioner Guide

  95

• Cylinder Head Disassembly

  95

• Cylinder Head Distortion

  97

• Valve Stem Runout

  97

• Valve Head Radial Runout

  97

• Valve Face Wear

  98

• Valve Stem Deflection

  98

• Valve Stem Wear

  98

• Valve Guide Servicing

  99

• Valve Seat Width

  100

• Valve Seat Servicing

  100

• Valve Stem End Condition

  102

• Valve Springs

  102

• Cylinder Head Reassembly

  103

• Intake Pipes

  104

• Cylinder Head Installation

  105

• Camshaft Installation

  108

• Cylinder Block/Pistons

  110

• Cylinder Block/Piston Removal

  111

• Cylinder Block/Piston Inspection

  112

• Cylinder Block Distortion

  112

• Cylinder Bore

  112

• Piston Diameter

  112

• Piston-To-Cylinder Clearance

  113

• Piston-Ring-To-Groove Clearance

  113

• Piston/Cylinder Block Installation

  114

• Piston Pins and Pin Bore

  114

• Oversize Piston Ring

  114

• Oversize Oil Ring

  114

• Piston/Cylinder Block

  116

• Clutch

  117

• Clutch Removal

  118

• Clutch Release Assembly Removal

  120

• Clutch/Clutch Release Assembly Inspection

  120

• Clutch Drive Plates

  120

• Clutch Driven Plates

  121

• Clutch Spring Free Length

  121

• Clutch Release Bearing

  121

• Clutch Release Assembly Installation

  122

• Clutch Installation

  123

• Starter System/Signal Generator

  125

• Starter Clutch Removal

  126

• Signal Generator Removal

  127

• Starter Clutch/Signal Generator Inspection

  127

• Signal Generator Installation

  128

• Starter Driven Gear Bearing Inspection

  128

• Signal Generator Inspection

  128

• Starter Clutch Installation

  129

• Starter Motor Removal

  130

• Starter Motor Inspection

  130

• Starter Motor Installation

  130

• Gearshift Linkage

  131

• Gearshift Linkage Removal

  132

• Gearshift Linkage Inspection

  133

• Gearshift Shaft/Gearshift Arm Inspection

  133

• Oil Seal Inspection

  133

• Oil Seal Replacement

  133

• Gearshift Shaft Hole Inspection

  134

• Gearshift Shaft Reassembly

  134

• Gearshift Linkage Installation

  135

• Crankcase/Transmission/Crankshaft/Conrods

  137

• Transmission/Crankshaft/Conrod Removal

  139

• Transmission Inspection and Service

  139

• Gearshift-Fork-To-Gearshift-Fork-Groove Clearance

  139

• Countershaft Assembly

  140

• Driveshaft Assembly

  141

• Conrod/Crankshaft Inspection

  146

• Conrod-Crank Pin Bearing Inspection and Service

  146

• Conrod Small End I.D.

  146

• Conrod Big End Side Clearance

  146

• Conrod-Crank Pin Bearing Selection

  147

• Bearing Selection Table

  148

• Conrod I.D. Specification

  148

• Crank Pin O.D. Specification

  148

• Bearing Thickness Specification

  148

• Crankcase-Crankshaft Bearing Inspection and Service

  149

• Bearing Assembly

  149

• Crankcase-Crankshaft Bearing Inspection

  149

• Crankcase-Crankshaft Bearing Selection

  149

• Crankshaft Thrust Clearance Adjustment

  152

• Crankshaft Runout

  153

• Left-Side Thrust Bearing Selection Table

  153

• Transmission/Crankshaft/Conrod Installation

  154

• Engine Lubrication System

  155

• Oil Pump Removal

  156

• Oil Pump Inspection

  156

• Oil Pump Installation

  156

• Oil Sump Filter/Oil Pressure Regulator Removal

  156

• Oil Pressure Regulator Inspection

  157

• Oil Sump Filter Cleaning

  157

• Oil Pan

  157

• Oil Sump Filter/Oil Pressure Regulator Installation

  158

• Oil Pressure Switch/Oil Cooler Removal

  159

• Oil Pressure Switch Inspection

  159

• Oil Cooler Hose Inspection

  160

• Oil Cooler Inspection and Cleaning

  160

• Oil Jet

  161

• Oil Jet Removal

  162

• Oil Jet Inspection

  162

• Oil Jet Installation

  162

• Engine Lubrication System Chart

  163

• Cylinder Head Cooling System Chart

  165

• Cylinder Head Cooling System

  166

• Fuel System

  167

• Fuel Tank Removal

  169

• Fuel Tank Remounting

  169

• Vacuum Fuel Valve

  170

• Vacuum Fuel Valve Removal

  170

• Vacuum Fuel Valve Inspection and Cleaning

  171

• Vacuum Fuel Valve Remounting

  171

• Fuel Level Gauge Removal

  171

• Fuel Level Gauge Remounting

  171

• Fuel Filter Removal

  172

• Fuel Filter Inspection

  172

• Fuel Filter Remounting

  172

• Carburetor Construction

  173

• Carburetor Specifications

  174

• I.D. No. Location

  175

• Diaphragm and Piston Operation

  176

• Lower Position of the Piston Valve

  176

• Upper Position of the Piston Valve

  176

• Slow System

  177

• Main System

  178

• Starter (Enricher) System

  179

• Float System

  179

• Pilot Screw Removal

  184

• Carburetor Cleaning

  185

• Carburetor Inspection

  185

• Needle Valve Inspection

  186

• Float Height Adjustment

  186

• Throttle Position Sensor Inspection

  186

• Throttle Valve

  187

• Pilot Screw

  187

• Carburetor Engagement

  187

• Throttle Position Sensor Positioning

  188

• Carburetor Clamps

  188

• Calibrating the Carburetor Balancer

  189

• Chassis

  192

• Exterior Parts Construction

  193

• Lower Fairings Removal

  194

• Upper Fairings Removal

  194

• Frame Cover Removal

  196

• Front Wheel Construction

  197

• Front Wheel Removal

  199

• Front Wheel Inspection and Disassembly

  200

• Front Axle

  201

• Front Wheel Remounting

  202

• Front Fork Construction

  204

• Front Fork Removal and Disassembly

  205

• Front Fork Inspection

  207

• Inner and Outer Tube

  207

• Fork Spring

  207

• Damper Rod Ring

  207

• Front Fork Reassembly and Remounting

  208

• Slide Metals and Oil and Dust Seals

  208

• Damper Rod Bolt

  209

• Fork Oil

  209

• Suspension Setting

  211

• Steering Construction

  212

• Steering Removal and Disassembly

  212

• Steering Inspection and Disassembly

  214

• Steering Reassembly and Remounting

  215

• Steering Stem Nut

  216

• Handlebar and Front Fork

  216

• Steering Tension Adjustment

  217

• Rear Wheel Construction

  218

• Rear Wheel Removal

  220

• Rear Wheel Inspection and Disassembly

  221

• Rear Sprocket Mounting Drum Bearing

  221

• Wheel Bearings Reassembly

  222

• Rear Axle

  222

• Cushion

  222

• Rear Sprocket

  222

• Rear Sprocket Mounting Drum Bearing and Dust Seal

  223

• Rear Suspension Construction

  224

• Rear Suspension Removal

  226

• Rear Suspension Inspection and Disassembly

  227

• Chain Buffer

  227

• Swingarm Needle Bearings

  227

• Cushion Lever Needle Bearings

  228

• Cushion Lever and Cushion Lever Rods

  228

• Pivot Shaft

  229

• Rear Shock Absorber

  229

• Rear Suspension Final Inspection and Adjustment

  231

• Rear Suspension Setting

  231

• Front Brake Construction

  232

• Brake Pad Replacement

  233

• Brake Fluid Replacement

  234

• Brake Caliper Removal and Disassembly

  234

• Brake Caliper Inspection

  235

• Brake Caliper Reassembly and Remounting

  236

• Rubber Parts

  236

• Brake Caliper Holder

  236

• Brake Disc Inspection

  237

• Master Cylinder Removal and Disassembly

  238

• Master Cylinder Inspection

  239

• Master Cylinder Reassembly and Remounting

  240

• Rear Brake Construction

  242

• Tire Removal

  249

• Wheels Inspection

  251

• Tires Inspection

  251

• Valve Inspection

  251

• Tire Installation

  252

• Valve Installation

  252

• Electrical System

  254

• Cautions in Servicing

  255

• Connectors

  255

• Couplers

  255

• Clamps

  255

• Connecting the Battery

  256

• Battery Wiring Procedure

  256

• Using the Multi Circuit Tester

  257

• Location of Electrical Components

  258

• Charging System Description (Generator with IC Regulator)

  260

• Trouble Shooting

  261

• Battery Runs down Quickly

  261

• Battery Current Leak Inspection

  262

• Charging Output Inspection

  262

• Generator

  263

• Generator Removal and Disassembly

  264

• Rotor Bearings Inspection

  266

• Generator Driven Gear Dampers

  267

• Stator Coil Continuity Check

  267

• Rotor Coil Continuity Check

  267

• Slip Rings

  267

• Carbon Brushes

  268

• Rectifier

  268

• IC Regulator

  268

• Generator Reassembly and Remounting

  269

• Starter System Description

  271

• Side-Stand/Ignition Interlock System Description

  271

• Starter Motor will Not Run

  273

• Starter Motor Removal and Disassembly

  274

• Starter Motor Reassembly and Remounting

  275

• Commutator

  275

• Armature Coil Inspection

  275

• Starter Relay Inspection

  276

• Side-Stand/Ignition Interlock System Part Inspection

  277

• Neutral Switch

  278

• Side-Stand Switch

  278

• Turn Signal/Side-Stand Relay

  278

• Side-Stand Relay Inspection

  279

• Diode Inspection

  279

• Ignition System (Digital Ignitor) Description

  280

• No Spark or Poor Spark

  281

• Ignition Coil Primary Peak Voltage Inspection

  282

• Ignition Coil Resistance

  283

• Signal Generator Peak Voltage

  284

• Signal Generator

  285

• Combination Meter Removal

  286

• Combination Meter Disassembly

  287

• Combination Meter Inspection

  287

• Fuel Meter Inspection

  289

• Fuel Level Gauge Inspection

  289

• Speedometer Inspection

  290

• Speed Sensor Inspection

  290

• Oil Pressure Indicator Inspection

  291

• Lamps

  292

• Headlight Bulb Replacement

  292

• Brake Light/Taillight and License Plate Light

  293

• Turn Signal Lights

  293

• Switches

  295

• Battery Specifications

  296

• Battery Removal

  296

• Battery Remounting

  296

• Initial Charging

  297

• Filling Electrolyte

  297

• Recharging Operation

  299

• Servicing Information

  300

• Troubleshooting Engine

  301

• Carburetor Troubleshooting

  305

• Chassis Troubleshooting

  305

• Brakes Troubleshooting

  306

• Electrical Troubleshooting

  307

• Battery Troubleshooting

  308

• Wiring Diagram for E-02

  309

• Wiring Diagram for E-04, 17, 18, 22, 25, 34

  310

• Wiring Diagram for E-24

  311

• Wiring Diagram for E-03, 28, 33

  312

• Wire Harness Routing

  313

• Cable Routing

  315

• Fuel System Hose Routing

  316

• Oil Hose Routing

  317

• Front Brake Hose Routing

  318

• Rear Brake Hose Routing

  319

• Pair (Air Supply) System Hose Routing (for E-18)

  320

• Brake Pedal

  321

• Side-Stand Spring

  322

• Fairing Set up

  323

• Frame Cover Set up

  324

• Frame Cover Cushion

  324

• Heat Shield and Cushion

  325

• Heat Shield

  326

• Fuel Tank Molding

  326

• Special Tools

  327

• Tightening Torque Engine

  330

• Tightening Torque Chassis

  331

• Tightening Torque Chart

  332

• Service Data Valve + Guide

  333

• Service Data Camshaft + Cylinder Head

  334

• Service Data Cylinder + Piston + Piston Ring

  334

• Service Data Conrod + Crankshaft

  335

• Service Data Oil Pump

  335

• Service Data Clutch

  336

• Service Data Transmission + Drive Chain

  336

• Service Data Carburetor

  337

• Service Data Electrical

  338

• Service Data Wattage

  338

• Service Data Brake + Wheel

  339

• Service Data Suspension

  340

• Service Data Tire Pressure

  340

• Service Data Fuel + Oil

  340

• Emission Control Information

  341

• Emission Control Carburetor Components

  342

• Evaporative Emission Control System (California Model Only)

  343

• Canister Hose Routing (California Model Only)

  344

• Evaporative Emission Control System Inspection

  345

• Hoses

  345

• Canister

  345

• Purge Control Valve

  345

• Pair (Air Supply) System Diagram

  346

• Pair (Air Supply) System Hose Routing

  347

• Pair (Air Supply) System Inspection

  348

• Hoses and Pipes

  348

• Pair Cleaner

  348

• Pair Reed Valve

  348

• Pair Control Valve

  349

• GSX600FX/Y (’99/’00 Model)

  350

• GSX600FX/Y (’99/’00 Model) Specifications

  351

• GSX600FK1 (’01 Model)

  362

• GSX600FK1 (’01 Model) Specifications

  363

• GSX600FK1 (’01 Model) Service Data

  364

• GSX600FK1 (’01 Model) Change

  373