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GSX-R600
99500-35100-01E
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FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSX-R600 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION 1 nents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to PERIODIC MAINTENANCE 2 familiarize yourself with the motorcycle and its main- tenance. Use this section as well as other sections to use as a guide for proper inspection and service. ENGINE 3 This ma
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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 oth
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SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Apply THREAD LOCK SUPER “1360”. Data beside it indicates specified 99000-32130 torque. Apply oil. Use engine oil unless other- Use engine coolant. wise specified. 99000-99032-11X (Except USA) Apply molybdenum oil solution. Use fork oil. (Mixture of engine oi
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ABBREVIATIONS USED IN THIS MANUAL A E ABDC : After Bottom Dead Center ECM : Engine Control Module AC : Alternating Current Engine Control Unit (ECU) ACL : Air Cleaner, Air Cleaner Box (FI Control Unit) API : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp. ATM Pressure : Atmospheric Pressure Sensor (WTS) : Atmospheric Pressure sensor EVAP : Evaporative Emission (APS, AP Sensor) EVAP Canister : Evaporative Emission A/F
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M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (LED) Min : Minimum N NOX : Nitrogen Oxides O OHC : Over Head Camshaft OPS : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R RH : Right Hand ROM : Read Only Memory S SAE : Society of Automotive Engineers SDS : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) ST Valve : Secondary Throttl
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WIRE COLOR B : Black G : Green P :Pink Bl : Blue Gr : Gray R : Red Br : Brown Lbl : Light blue W : White Dg : Dark green Lg : Light green Y : Yellow Dgr : Dark gray O : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/G : Black with Green tracer B/Lg : Black with Light green tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer Bl/W : Blue with Wh
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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...
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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 mes- sages 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
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GENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * 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
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1-4 GENERAL INFORMATION SUZUKI GSX-R600K6 (’06-MODEL) RIGHT SIDE LEFT SIDE Difference between illustrations and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These num- bers are required especially for registering the machine and ordering spare parts.
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GENERAL INFORMATION 1-5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER COUNTRIES) Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasol
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1-6 GENERAL INFORMATION FRONT FORK OIL Use fork oil SS-05 or an equivalent fork oil. ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times
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GENERAL INFORMATION 1-7 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. Keep to these break-in engine speed limits: Initial 800 km
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1-8 GENERAL INFORMATION INFORMATION LABELS GSX-R600 GSX-R600UE GSX-R600UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Manual notice label A (For E-03, 33) 6 Screen label A (Except E-19 ) 7 Screen label A (For E-28) A 8 Screen label A (For E-19) A 9 Warning steering label A (For E-03, 33) 0 Warning steering label A (Except E-03, 33) A A A Tire information label A (For E-03, 33) B T
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GENERAL INFORMATION 1-9 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length .......................................................................... 2 040 mm (80.3 in) Overall width ........................................................................... 715 mm (28.1 in) Overall height .......................................................................... 1 125 mm (44.3 in) Wheelbase .............................................................................. 1 400 mm (55.1 in
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1-10 GENERAL INFORMATION CHASSIS Front suspension .................................................................... Inverted telescopic, coil spring, oil damped Rear suspension ..................................................................... Link type, coil spring, oil damped Front fork stroke...................................................................... 120 mm (4.7 in) Rear wheel travel.................................................................... 130 mm (5.1 in) Steer
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PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE .................................................... 2- 2 2 PERIODIC MAINTENANCE CHART..................................................... 2- 2 LUBRICATION POINTS ........................................................................ 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ....................................... 2- 4 AIR CLEANER..........................................................................
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2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT (For E-28): The periodic maintenance intervals and service requirements have been estab- lished in accordance with EPA regulations. Following these instructions will ensure that
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PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Brake pedal pivot and footrest pivot Clutch lever holder Footrest pivot and Side-stand pivot Drive chain gearshift lever pivot and spring hook NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts
