2001-2002

SUZUKI

GSX-R600

SERVICEMANUAL

_{t~~n1~11m'1m~u~~;1~mr1}

^{99500-35080-01E}

FOREWORD

ThismanualcontainsanintroductorydescriptionontheSUZUKIGSX-R600andproceduresforitsinspection/serviceandoverhaulofitsmaincom•ponents.

Otherinformationconsideredasgenerallyknown

isnotincluded.

ReadtheGENERALINFORMATIONsectiontofa•miliarizeyourselfwiththemotorcycleanditsmainte•nance.Usethissectionaswellasothersectionstouseasaguideforproperinspectionandservice.Thismanualwillhelpyouknowthemotorcyclebet•tersothatyoucanassureyourcustomersoffastandreliableservice.

•Thismanualhasbeenpreparedonthebasisofthelatestspecificationsatthetimeofpub•lication.Ifmodificationshavebeenmadesincethen,differencesmayexistbetweenthecontentofthismanualandtheactualmotor•cycle.

•Illustrationsinthismanualareusedtoshow

thebasicprinciplesofoperationandworkpro•cedures.Theymaynotrepresenttheactualmotorcycleexactlyindetail.

*Thismanualiswrittenforpersonswhohave

enoughknowledge,skillsandtools,includingspecialtools,forservicingSUZUKImotor•cycles.Ifyoudonothavetheproperknowl•edgeandtools,askyourauthorizedSUZUKImotorcycledealertohelpyou.

AWARNING

Inexperiencedmechanicsormechanicswithoutthepropertoolsandequipmentmaynotbeabletoproperlyperformtheservicesdescribedinthismanual.Improperrepairmayresultininjurytothemechanicandmayrenderthemotorcycleunsafefortheriderandpassenger.

SUZUKIMOTORCORPORATION

MotorcycleServiceDepartment

GROUPINDEX

GENERALINFORMATIONPERIODICMAINTENANCE

ENGINE

FlSYSTEMANDINTAKEAIRSYSTEM

COOLINGANDLUBRICATIONSYSTEM

CHASSIS

ELECTRICALSYSTEMSERVICINGINFORMATIONWIRINGDIAGRAM

HOWTOUSETHISMANUALTOLOCATEWHATYOUARELOOKINGFOR:

1.Thetextofthismanualisdividedintosections.

2.ThesectiontitlesarelistedintheGROUPINDEX.

3.Holdingthemanualasshownattherightwillallowyoutofindthefirstpageofthesectioneasily.

4.Thecontentsarelistedonthefirstpageofeachsectiontohelpfindtheitemandpageyouneed.

COMPONENTPARTSANDWORKTOBEDONE

Underthenameofeachsystemorunit,isitsexplodedview.Workinstructionsandotherserviceinformationsuchasthetighteningtorque,lubricatingpointsandlockingagentpoints,areprovided.

_{Example:Frontwheel}

_'DBrakedisc

12'>Dustseal

@Bearing

@Spacer

_r~Spacernut

IDFrontwheel

@Frontaxle

<"§;'Brakediscbolt(Front)

ITEM	N·m	kgf·m	lb-ft
~'PY	100	10.0	72.5
~~	23	2.3	16.5

SYMBOL

Listedinthetablebelowarethesymbolsindicatinginstructionsandotherinformationnecessaryforservic•

ing.Themeaningofeachsymbolisalsoincludedinthetable.

^(!J=

SYMBOL^{DEFINITIONSYMBOLDEFINITION}

Torquecontrolrequired.ApplyTHREADLOCKSUPERDatabesideitindicatesspecified"1360".

_torque.99000-32130

-ml1

_[l'

Applyoil.Useengineoilunlessotherwisespecified.

Applymolybdenumoilsolution.(MixtureofengineoilandSUZUKI

_-ml

_e

_{Useenginecoolant.}

^{99000-99032-11x}

Useforkoil.

99000-99001-SSS

MOLYPASTEinaratioof1:1)^{(99000-99044-1OG)}

ApplySUZUKISUPERGREASE"A".

_99000-25010

^~_~

Applyorusebrakefluid.

ApplySUZUKIMOLYPASTE.

_99000-25140

~

Measureinvoltagerange.

~

ApplySUZUKIBOND"12078".

^~99000-31140_~

Measureincurrentrange.

•

~121s]

ApplySUZUKIBOND"1215"

99000-31110

Measureindiodetestrange.

_~

~·~

ApplyTHREADLOCKSUPER"1303".

•^Ifooh

_99000-32030^~

Measureincontinuitytestrange.

ApplyTHREADLOCKSUPER_{Usespecialtool."}1322".

_99000-32110

•

ApplyTHREADLOCK"1342".^{Indicationofservicedata.}

99000-32050

ABBREVIATIONS		MAYBE	USED	IN
THISMANUAL
A ABDC:After	BottomDead		Center		E		ECM	:EngineControlModule

^{AC:AlternatingCurrent}_{EngineControlUnit(ECU)}

^AGL:AirCleaner,AirCleanerBox^{(FlControlUnit)}

_{API:AmericanPetroleumInstitute}^ECTSensor:EngineCoolantTemperature

_{ATDC:AfterTopDeadCenter}^{Sensor(ECTS),WaterTemp.}

Sensor(WTS)

^ATMPressure:AtmosphericPressure

AtmosphericPressure

_{Sensor(APS,APSensor)}

^EVAP:EvaporativeEmission

-

_{EVAPCanister:EvaporativeEmission}

Canister(Canister)^A/F:AirFuelMixture

F

^BFl:FuelInjection,FuelInjector

^BBDC:BeforeBottomDeadCenter_FP:FuelPump

^{BTDC:BeforeTopDeadCenterFPR:}FuelPressureRegulator

B+:BatteryPositiveVoltage_{FPRelay:FuelPumpRelay}

c_G

^CKPSensor:CrankshaftPositionSensor_{GEN:Generator}

^(CKPS)GND:Ground

^{CKT:CircuitGPSwitch:}GearPositionSwitch

^CLPSwitch_{:ClutchLeverPositionSwitch}

(ClutchSwitch)_H

^CMPSensor:CamshaftPositionSensor_{HC:Hydrocarbons}

(CMPS)

^co:CarbonMonoxide

_{CPU:CentralProcessingUnit}^IAPSensor:IntakeAirPressure

Sensor(IAPS)

^DIATSensor:IntakeAirTemperature

^DC:DirectCurrent^{Sensor(IATS)DMC:}DealerModeCoupler^IG:Ignition

_{DOHC:DoubleOverHeadCamshaft}

_L

^{DRL:DaytimeRunningLight}_{LCD:LiquidCrystalDisplay}

^LED:LightEmittingDiode

(MalfunctionIndicatorLamp)^LH:LeftHand

M

MAL-Code^{:MalfunctionCode}

(DiagnosticCode)Max^:Maximum

MIL^{:MalfunctionIndicatorLamp}

(LED)

_Min:Minimum

N

_NOx^{:NitrogenOxides}

0

OHC^{:OverHeadCamshaft}

_OPS^{:OilPressureSwitch}

p

PCV^{:PositiveCrankcaseVentilation}

_{(CrankcaseBreather)}

R

RH^:RightHand

ROM^{:ReadOnlyMemory}

s

SAE^{:SocietyofAutomotive}

Engineers

STCSystem^{:SecondaryThrottleControlSystem}

(STCS)

STCUnit^{:SecondaryThrottleControlUnit}

(STCU)

STPSensor^{:SecondaryThrottlePositionSensor}

(STPS)

STValve^{:SecondaryThrottleValve(STV)STV}Actuator^{:SecondaryThrottleValveActuator}

_(STVA)

T

TOSensor^{:TipOverSensor(TOS)}

TPSensor^{:ThrottlePositionSensor}

(TPS)

Generalinformation

_CONTENTS

WARNING/CAUTION/NOTE.............................................................	1-	2
GENERALPRECAUTIONS..............................................................	1-	2
SUZUKIGSX-R600K1(2001-MODEL).............................................	1-	4
SERIALNUMBERLOCATION.........................................................	1-	4
FUEL,OILANDENGINECOOLANTRECOMMENDATION...........	1-	5
FUEL	1-	5
ENGINEOIL.....•........	1-	5
BRAKEFLUID	1-	5
FRONTFORKOIL	1-	5
ENGINECOOLANT.......................................................................	1-	6
WATERFORMIXING....................................................................	1-	6
ANTI-FREEZE/ENGINECOOLANT..............................................	1-	6
LIQUIDAMOUNTOFWATER/ENGINECOOLANT.....................	1-	6
BREAK-INPROCEDURES...............................................................	1-	6
CYLINDERIDENTIFICATION...........................................................	1-	6
INFORMATIONLABELS..................................................................	1-	7
SPECIFICATIONS.............................................................................	1-	8

COUNTRYANDAREACODES1-10

1·2GENERALINFORMATION

WARNING/CAUTION/NOTE

Pleasereadthismanualandfollowitsinstructionscarefully.Toemphasizespecialinformation,thesymbolandthewordsWARNING,CAUTIONandNOTEhavespecialmeanings.Payspecialattentiontothemes•sageshighlightedbythesesignalwords.

.AWARNING

Indicatesapotentialhazardthatcouldresultindeathorinjury.

,ACAUTIONI

Indicatesapotentialhazardthatcouldresultinmotorcycledamage.

NOTE:

Indicatesspecialinformationtomakemaintenanceeasierorinstructionsclearer.

Pleasenote,however,thatthewarningsandcautionscontainedinthismanualcannotpossiblycoverallpotentialhazardsrelatingtotheservicing,orlackofservicing,ofthemotorcycle.InadditiontotheWARN·INGSandCAUTIONSstated,youmustusegoodjudgementandbasicmechanicalsafetyprinciples.Ifyouareunsureabouthowtoperformaparticularserviceoperation,askamoreexperiencedmechanicforad•vice.

GENERALPRECAUTIONS

.AWARNING

*Properserviceandrepairproceduresareimportantforthesafetyoftheservicemechanicandthesafetyandreliabilityofthemotorcycle.

*When2ormorepersonsworktogether,payattentiontothesafetyofeachother.

*Whenitisnecessarytoruntheengineindoors,makesurethatexhaustgasisforcedoutdoors.

*Whenworkingwithtoxicorflammablematerials,makesurethattheareayouworkiniswell-ventilatedandthatyoufollowallofthematerialmanufacturer'sinstructions.

*Neverusegasolineasacleaningsolvent.

•Toavoidgettingburned,donottouchtheengine,engineoil,radiatorandexhaustsystemuntiltheyhavecooled.

*Afterservicingthefuel,oil,enginecoolant,exhaustorbrakesystems,checkalllinesandfit•

_{tingsrelatedtothesystemforleaks.}

...J

IACAUTIONI

*Ifpartsreplacementisnecessary,replacethepartswithSuzukiGenuinePartsortheirequiva•

lent.

*Whenremovingpartsthataretobereused,keepthemarrangedinanorderlymannersothattheymaybereinstalledintheproperorder.

*Besuretousespecialtoolswheninstructed.

*Makesurethatallpartsusedinreassemblyareclean.Lubricatethemwhenspecified.

*Usethespecifiedlubricant,bond,orsealant.

*Whenremovingthebattery,disconnectthenegativecablefirstandthenthepositivecable.

*Whenreconnectingthebattery,connectthepositivecablefirstandthenthenegativecable,andcoverthepositiveterminalwiththeterminalcover.

*Whenperformingservicetoelectricalparts,disconnectthebatterynegativecableunlessthe

serviceprocedurerequiresthebatterypower.

•Whentighteningcylinderheadandcrankcaseboltsandnuts,tightenthelargersizesfirst.

Alwaystightentheboltsandnutsdiagonallyfromtheinsideworkingoutandtothespecifiedtighteningtorque.

*Wheneveryouremoveoilseals,gaskets,packing,0-rings,lockingwashers,self-lockingnuts,

cotterpins,circlips,andcertainotherpartsasspecified,besuretoreplacethemwithnewones.Also,beforeinstallingthesenewparts,besuretoremoveanyleftovermaterialfromthematingsurfaces.

*Neverreuseacirclip.Wheninstallinganewcirclip,takecarenottoexpandtheendgaplarger

thanrequiredtoslipthecirclipovertheshaft.Afterinstallingacirclip,alwaysensurethatitiscompletelyseatedinitsgrooveandsecurelyfitted.

•Useatorquewrenchtotightenfastenerstothespecifiedtorque.Wipeoffgreaseandoilifa

threadissmearedwiththem.

_{*Afterreassembling,checkpartsfortightnessandproperoperation.}

....

*Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,enginecoolantandotherfluids:batteries,andtires.

*Toprotecttheearth'snaturalresources,properlydisposeofusedmotorcyclesandparts.

1-4GENERALINFORMATION

SUZUKIGSX-R600K1(2001-MODEL)

_RIGHTSIDE

_LEFTSIDE

•Differencebetweenphotographandactualmotorcycledependsonthemarkets.

SERIALNUMBERLOCATION

TheframeserialnumberorV.l.N.(VehicleIdentificationNumber)

®isstampedontherightsideofthesteeringheadpipe.Theengineserialnumber@islocatedontherearsideofthecrank•case.Thesenumbersarerequiredespeciallyforregisteringthemachineandorderingspareparts.

GENERALINFORMATION1-5

FUEL,OILANDENGINECOOLANTRECOMMENDATION

FUEL(FORUSAANDCANADA}

Useonlyunleadedgasolineofatleast87pumpoctane(R~M)or91octaneorhigherratedbytheresearchmethod.GasolinecontainingMTBE(MethylTertiaryButylEther),lessthan10%ethanol,orlessthan5%methanolwithappropriatecosolventsandcorrosioninhibitorispermissible.

FUEL(FORTHEOTHERCOUNTRIES)

Gasolineusedshouldbegraded91octane(ResearchMethod)orhigher.Anunleadedgasolineisrecom-mended.

ENGINEOIL(ForU.S.A.model}

_{SUZUKIrecommendstheuseofSUZUKIPERFORMANCE4}

MOTOROILoranoilwhichisratedSForSGundertheAPI(AmericanPetroleumInstitute)serviceclassification.Therecom•mendedviscosityisSAE1OW/40.IfanSAE1OW/40oilisnotavailable,selectandalternativeaccordingtotherightchart.

ENGINEOIL(Fortheothermodels)

Useapremiumquality4-strokemotoroiltoensurelongerser•vicelifeofyourmotorcycle.UseonlyoilswhichareratedSForSGundertheAPIserviceclassification.

TherecommendedviscosityisSAE1OW-40.IfanSAE1OW-40

motoroilisnotavailable,selectanalternativeaccordingtothefollowingchart.

BRAKEFLUID

_{UseDOT4brakefluid.}

_..

_..

^MULTIGRADE_"•

_''

10W30

_II

_{•c-30-20-10o10203040}

_TEMP.

^{°F-2241432506886104}

AWARNING

Sincethebrakesystemofthismotorcycleisfilledwithaglycol-basedbrakefluidbythemanu•facturer,donotuseormixdifferenttypesoffluidsuchassilicone-basedandpetroleum-basedfluidforrefillingthesystem,otherwiseseriousdamagewillresult.

Donotuseanybrakefluidtakenfromoldorusedorunsealedcontainers.

Neverre-usebrakefluidleftoverfromapreviousservicing,whichhasbeenstoredforalongperiod.

FRONTFORKOIL

UseforkoilSS-8(#10)oranequivalentforkoil.

ENGINECOOLANT

Useananti-freeze/enginecoolantcompatiblewithanaluminumradiator,mixedwithdistilledwateronly.

WATERFORMIXING

Usedistilledwateronly.Waterotherthandistilledwatercancorrodeandclogthealuminumradiator.

ANTI-FREEZE/ENGINECOOLANT

Theenginecoolantperiormasacorrosionandrustinhabitaswellasanti-freeze.Therefore,theenginecoolantshouldbeusedatalltimeseventhoughtheatmospherictemperatureinyourareadoesnotgodowntofreezingpoint.

SuzukirecommendstheuseofSUZUKICOOLANTanti-freeze/enginecoolant.Ifthisisnotavailable,useanequivalentwhichiscompatiblewithanaluminumradiator.

LIQUIDAMOUNTOFWATER/ENGINECOOLANT

Solutioncapacity(total):2400ml(2.5/2.1US/Impqt)

Forenginecoolantmixtureinformation,refertocoolingsystemsection.(c:::.r5·2)

I.ACAUTIONI

Mixingofanti-freeze/enginecoolantshouldbelimitedto60%.Mixingbeyonditwouldreduceitsefficiency.Iftheanti-freeze/enginecoolantmixingratioisbelow50%,rustinhabitingperformanceisgreatlyreduced.Besuretomixitabove50%eventhoughtheatmospherictemperaturedoesnotgodowntothefreezingpoint.

BREAK-INPROCEDURES

Duringmanufactureonlythebestpossiblematerialsareusedandallmachinedpartsarefinishedtoaveryhighstandardbutitisstillnecessarytoallowthemovingpartsto"BREAK-IN"beforesubjectingtheenginetomaximumstresses.Thefutureperformanceandreliabilityoftheenginedependsonthecareandrestraintexercisedduringitsearlylife.Thegeneralrulesareasfollows.

_{•Keeptothesebreak-inprocedures:}

Initial	800km	(500miles):	Below	7000r/min
Upto Overto	1600km 1600km	(1000miles):(1000miles):	Below Below	10500r/min 14000r/min

•Uponreachinganodometerreadingof1600km(1000miles)youcansubjectthemotorcycletofullthrottleoperation.However,donotexceed14000r/minatanytime.

CYLINDERIDENTIFICATION

ThefourcylindersofthisengineareidentifiedasNo.1,No.2,No.3andNo.4cylinder,ascountedfromlefttoright(asviewedbytheriderontheseat).