MOTORCYCLE SERVICE MANUAL

MODELS COVERED:

GSX-R600 (U.S., California, Canada, U.K. and Europe Models) (2001-2005)
GSX-R600 Alstare (U.S., California and Canada Models) (2003)

This Suzuki GSX-R600 Manual is 480 pages.

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 / Leak down test / Clutch / Gearshift linkage / Transmission / Fuel system / Electrical testing / Electrical troubleshooting / Steering and suspension / Brake system / Specifications

CHAPTER THREE / 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

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 release mechanism / Clutch cable / Clutch lever assembly / Specifications

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

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 / Steering head and stem / Steering head bearing race / Steering stem race / 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 section / Front engine cover / Center panel / Bracket cover / Mirror / Windshield / Front fairing / Fairing bracket / Intake duct / Side panel / Tail piece / Front fender / Sidestand / Specifications

COLOR WIRING DIAGRAMS