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Suzuki Intruder VS600GL User Manual

Suzuki Intruder VS600GL
277 pages
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Table of Contents

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Suzuki Intruder VS600GL Specifications

General IconGeneral
Engine Displacement583 cc
Fuel SystemCarburetor
Transmission5-speed
Final DriveShaft
Front SuspensionTelescopic, coil spring, oil damped
Rear SuspensionSwingarm, coil spring, oil damped
Front BrakeSingle disc
Rear BrakeDrum
Liquid-cooledYes
SOHC/DOHCSOHC
Starting SystemElectric
LubricationWet sump
Rear Tire140/90-15
Ground Clearance140 mm (5.5 inches)
Engine Type4-stroke, V-twin
Maximum Power45 hp @ 7, 500 rpm
Maximum Torque52.0 Nm (5.3 kgf-m or 38.4 ft.lbs) @ 5000 RPM
Seat Height700 mm
IgnitionElectronic ignition

Summary

General Information

Warning, Caution, and Note Symbols

Explains the meaning of warning, caution, and note symbols used in the manual.

General Precautions for Servicing

Lists important safety precautions for servicing the motorcycle.

Suzuki VS600GLS Model Identification

Specifies the model year and designation covered by the manual.

Serial Number Location

Indicates where to find the frame and engine serial numbers.

Fluid Recommendations

Recommends specific types and grades of fuel, oil, and coolant.

Break-in Procedures

Guidelines for the initial break-in period of the motorcycle.

Specifications and Data

Provides key technical specifications and dimensions for the motorcycle.

Periodic Maintenance

Periodic Maintenance Schedule

Outlines recommended service intervals based on mileage and time.

Periodic Maintenance Chart

Detailed table showing service items and required actions at intervals.

Lubrication Points

Illustrates and lists key points requiring lubrication on the motorcycle.

Maintenance and Tune-Up Procedures

General procedures for routine maintenance and tune-ups.

Battery Maintenance

Details on battery inspection, maintenance, and charging.

Air Cleaner Service

Procedure for inspecting and cleaning the air cleaner element.

Valve Clearance Adjustment

Instructions for checking and adjusting valve clearance.

Spark Plug Service

Guide to spark plug inspection, gap adjustment, and replacement.

Engine Oil and Oil Filter Change

Steps for changing engine oil and oil filter.

Brake System Maintenance

Maintenance and inspection procedures for the braking system.

Tire Inspection and Pressure

Information on tire inspection, tread depth, and pressure.

Compression Pressure Check

Procedure for checking engine compression pressure.

Engine Service

Engine Removal and Reinstallation

Detailed steps for removing and reinstalling the engine.

Engine Disassembly Procedures

Step-by-step guide for disassembling the engine.

Cylinder Head Cover Service

Procedures for inspecting and servicing the cylinder head cover.

Piston Ring to Groove Clearance

How to measure piston ring to groove clearance.

Conrod-Crank Pin Bearing Selection

Guidelines for selecting conrod-crank pin bearings.

Camshaft Timing Adjustment

Procedure for setting the camshaft timing.

Shaft Drive System

Shaft Drive Overview

Exploded view and diagram of the shaft drive system.

Secondary Bevel Gears Construction

Detailed breakdown of the secondary bevel gear assembly.

Shaft Drive Removal and Disassembly

Steps for removing and disassembling shaft drive components.

Secondary Gears Shim Adjustment and Backlash

Procedure for adjusting backlash using shims.

Bevel Gear Tooth Contact

How to check and adjust tooth contact on bevel gears.

Final Assembly and Remounting

Steps for final assembly and remounting of the shaft drive.

Final Gear Shim Adjustment and Clearance

How to adjust final gear shims for clearance.

Fuel and Lubrication System

Fuel System Overview

Overview of the motorcycle's fuel delivery system.

Fuel Pump Inspection

Procedure for testing the fuel pump's electrical resistance.

Fuel Tank and Fuel Valve

Information on fuel tank removal and fuel valve mechanism.

Carburetor Construction and Specifications

Exploded views and technical specifications for carburetors.

Carburetor Balancing

Procedure for synchronizing the carburetors.

Lubrication System Overview

Overview of the engine lubrication system and components.

Cooling System

Cooling System Description

Description of the cooling system's function and components.

Cooling System Construction

Exploded view of the cooling system components.

Engine Coolant Specifications

Information on engine coolant type, mixture, and specifications.

Cooling System Removal and Disassembly

Procedures for removing and disassembling the cooling system.

Thermostat Service

Inspection and removal procedures for the thermostat.

Radiator Service

Inspection and removal procedures for the radiator.

Chassis Components

Exterior Parts Removal

Procedures for removing exterior parts like frame covers and seats.

Front Wheel Service

Procedures for removing and inspecting the front wheel.

Front Brake System Maintenance

Procedures for front brake maintenance.

Master Cylinder Service

Procedures for master cylinder removal and disassembly.

Front Fork Service

Procedures for front fork removal, disassembly, and reassembly.

Steering System Maintenance

Procedures for steering system maintenance.

Rear Wheel and Brake Service

Procedures for rear wheel and brake maintenance.

Rear Suspension and Swingarm Maintenance

Procedures for rear suspension and swingarm maintenance.

Electrical System

Cautions in Electrical Servicing

General precautions for servicing electrical components.

Location of Electrical Components

Diagrams showing the location of electrical system parts.

Charging System

Description and function of the charging system.

Electrical System Troubleshooting

Troubleshooting guide for electrical system issues.

Ignition System Description

Description of the ignition system and its components.

Battery Specifications and Servicing

Specifications and servicing procedures for the battery.

Servicing Information

Troubleshooting Guide

Troubleshooting guide for various motorcycle systems.

Cable and Hose Routing

Diagrams showing routing of wires, cables, and hoses.

Special Tools for Servicing

Catalog of special tools required for servicing.

Tightening Torque Specifications

Torque specifications for various motorcycle components.

Service Data and Specifications

Technical data and specifications for various components.

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