GSX-R600 99500-35100-01E FOREWORD This manual contains an introductory description on the SUZUKI GSX-R600 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 customers of fast and reliable service. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY EXHAUST SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 A S P M E L Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. © COPYRIGHT SUZUKI MOTOR CORPORATION 2006 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel 1 2 3 4 5 6 7 A B Brake disc Collar Dust seal Bearing Spacer Front axle Front wheel Front axle bolt Brake disc bolt ITEM A B N·m 100 23 kgf-m 10.0 2.3 lb-ft 72.5 16.5 A S E L P M SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE "A" or equivalent grease. 99000-25010 Apply SUZUKI MOLY PASTE. 99000-25140 Apply SUZUKI BOND "1215" or equivalent bond. 99000-31110 SYMBOL DEFINITION Apply THREAD LOCK SUPER "1360". 99000-32130 Use engine coolant. 99000-99032-11X (Except USA) Use fork oil. 99000-99001-SS5 Apply SUZUKI BOND "1207B". 99104-31140 (USA) A S E L P M Apply or use brake fluid. Measure in voltage range. Measure in current range. Measure in resistance range. Apply SUZUKI BOND "1207B". 99000-31140 (Except USA) Measure in diode test range. Apply THREAD LOCK SUPER "1303". 99000-32030 Apply THREAD LOCK SUPER "1322" or equivalent thread lock. 99000-32110 Apply THREAD LOCK "1342". 99000-32050 Measure in continuity test range. Use special tool. Indication of service data. ABBREVIATIONS USED IN THIS MANUAL A ABDC AC ACL API ATDC ATM Pressure : After Bottom Dead Center : Alternating Current : Air Cleaner, Air Cleaner Box : American Petroleum Institute : After Top Dead Center : Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor) : Air Fuel Mixture E : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) EVAP : Evaporative Emission EVAP Canister : Evaporative Emission Canister (Canister) EXC System : Exhaust Control System (EXCS) EXC Valve : Exhaust Control Valve (EXCV) EXCV Actuator : Exhaust Control Valve Actuator (EXCVA) ECM A/F B BBDC BTDC B+ : Before Bottom Dead Center : Before Top Dead Center : Battery Positive Voltage F C CKP Sensor : Crankshaft Position Sensor (CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch (Clutch Switch) CMP Sensor : Camshaft Position Sensor (CMPS) CO : Carbon Monoxide CPU : Central Processing Unit A S P M G GEN GND GP Switch FI FP FPR FP Relay E L : Fuel Injection, Fuel Injector : Fuel Pump : Fuel Pressure Regulator : Fuel Pump Relay : Generator : Ground : Gear Position Switch H HC : Hydrocarbons D DC DMC DOHC DRL DTC : Direct Current : Dealer Mode Coupler : Double Over Head Camshaft : Daytime Running Light : Diagnostic Trouble Code I IAP Sensor IAT Sensor IG : Intake Air Pressure Sensor (IAPS) (MAP Sensor) : Intake Air Temperature Sensor (IATS) : Ignition L LCD LED LH : Liquid Crystal Display : Light Emitting Diode (Malfunction Indicator Lamp) : Left Hand M MAL-Code Max MIL Min : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum N NOX : Nitrogen Oxides O OHC OPS : Over Head Camshaft : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R RH ROM : Right Hand : Read Only Memory S SAE SDS STC System : Society of Automotive Engineers : Suzuki Diagnosis System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator (STVA) A S E L P M T TO Sensor TP Sensor : Tip-Over Sensor (TOS) : Throttle Position Sensor (TPS) WIRE COLOR B Bl Br Dg Dgr B/Bl B/G B/R B/Y Bl/G Bl/W Br/Y G/Bl G/W Gr/B Gr/W Lg/BI Lg/W O/BI O/R O/Y P/W R/Bl R/W W/Bl W/R Y/B Y/G Y/W : Black : Blue : Brown : Dark green : Dark gray : : : : : : : : : : : : : : : : : : : : : : : : G Gr Lbl Lg O : Green : Gray : Light blue : Light green : Orange B/Br B/Lg B/W Bl/B Bl/R Bl/Y G/B G/R G/Y Gr/R Gr/Y Lg/G O/B O/G O/W P/B R/B R/Y W/B W/G W/Y Y/Bl Y/R P R W Y :Pink : Red : White : Yellow Black with Blue tracer Black with Green tracer Black with Red tracer Black with Yellow tracer Blue with Green tracer Blue with White tracer Brown with Yellow tracer Green with Blue tracer Green with White tracer Gray with Black tracer Gray with White tracer Light green with Blue tracer Light green with White tracer Orange with Blue tracer Orange with Red tracer Orange with Yellow tracer Pink with White tracer Red with Blue tracer Red with White tracer White with Blue tracer White with Red tracer Yellow with Black tracer Yellow with Green tracer Yellow with White tracer A S P M : Black with Brown tracer : Black with Light green tracer : Black with White tracer : Blue with Black tracer : Blue with Red tracer : Blue with Yellow tracer : Green with Black tracer : Green with Red tracer : Green with Yellow tracer : Gray with Red tracer : Gray with Yellow tracer : Light green with Green tracer : Orange with Black tracer : Orange with Green tracer : Orange with White tracer : Pink with Black tracer : Red with Black tracer : Red with Yellow tracer : White with Black tracer : White with Green tracer : White with Yellow tracer : Yellow with Blue tracer : Yellow with Red tracer E L GENERAL INFORMATION 1-1 GENERAL INFORMATION 1 CONTENTS WARNING/CAUTION/NOTE......................................................................... 1- 2 GENERAL PRECAUTIONS .......................................................................... 1- 2 SUZUKI GSX-R600K6 ('06-MODEL)............................................................ 1- 4 SERIAL NUMBER LOCATION ..................................................................... 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION....................... 1- 5 FUEL (FOR USA AND CANADA).......................................................... 1- 5 FUEL (FOR OTHER COUNTRIES) ........................................................ 1- 5 ENGINE OIL (FOR USA)........................................................................ 1- 5 ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5 BRAKE FLUID........................................................................................ 1- 5 FRONT FORK OIL.................................................................................. 1- 6 ENGINE COOLANT................................................................................ 1- 6 WATER FOR MIXING............................................................................. 1- 6 ANTI-FREEZE/ENGINE COOLANT....................................................... 1- 6 LIQUID AMOUNT OF WATER/ENGINE COOLANT ............................. 1- 6 BREAK-IN PROCEDURES........................................................................... 1- 7 CYLINDER IDENTIFICATION....................................................................... 1- 7 INFORMATION LABELS .............................................................................. 1- 8 SPECIFICATIONS......................................................................................... 1- 9 DIMENSIONS AND DRY MASS............................................................. 1- 9 ENGINE .................................................................................................. 1- 9 DRIVE TRAIN ......................................................................................... 1- 9 CHASSIS ................................................................................................ 1-10 ELECTRICAL ......................................................................................... 1-10 CAPACITIES .......................................................................................... 1-10 A S P M E L COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE E-02 E-19 (GSX-R600) E-19 (GSX-R600U2) E-19 (GSX-R600U3) E-24 E-03 E-28 E-33 COUNTRY or AREA U.K. E.U. E.U. E.U. Australia U.S.A. (Except for California) Canada California (U.S.A.) EFFECTIVE FRAME NO. JS1CE111100100001 ­ JS1CE111100100001 ­ JS1CE211100100001 ­ JS1CE311100100001 ­ JS1CE121300100001 ­ JS1GN7DA 62100001 ­ JS1GN7DA 62100001 ­ JS1GN7DA 62100001 ­ 1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. * When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled. After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks. A S P M E L GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and ...