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Suzuki_GSX-R_600_K6-K7.pdf
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GSX-R600

9 9 5 0 0 - 3 5 1 0 0 - 0 1 E

FOREWORD

 

 

GROUP INDEX

 

This manual contains an introductory description on

 

 

the SUZUKI GSX-R600 and procedures for its

 

 

 

1

inspection/service and overhaul of its main compo-

GENERAL INFORMATION

nents.

 

 

Other information considered as generally known is

 

 

 

 

not included.

 

 

PERIODIC MAINTENANCE

2

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

 

 

tenance. Use this section as well as other sections

 

 

 

3

to use as a guide for proper inspection and service.

ENGINE

This manual will help you know the motorcycle bet-

 

 

ter so that you can assure your customers of fast

 

 

 

 

and reliable service.

 

 

FI SYSTEM DIAGNOSIS

4

 

 

 

* This manual has been prepared on the basis

 

 

 

 

 

 

of the latest specifications at the time of publi-

 

 

 

 

 

 

 

 

 

 

FUEL SYSTEM AND THROTTLE

5

cation. If modifications have been made since

 

 

then, differences may exist between the con-

 

 

BODY

 

 

6

tent of this manual and the actual motorcycle.

 

 

E

 

 

 

 

* Illustrations in this manual are used to show

 

 

L

 

 

 

 

 

the basic principles of operation and work

 

 

EXHAUST SYSTEM

 

procedures. They may not represent the

 

 

 

 

actual motorcycle exactly in detail.

 

P

 

 

 

COOLING AND LUBRICATION

7

* This manual is written for persons who have

 

 

M

 

SYSTEM

enough knowledge, skills and tools, including

 

 

 

special tools, for servicing SUZUKI motorcy-

 

 

 

 

 

 

 

 

cles. If you do not have the proper knowledge

 

 

 

 

S

 

 

 

8

and tools, ask your authorizedASUZUKI

 

 

CHASSIS

motorcycle dealer to help you.

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRICAL SYSTEM

9

Inexperienced mechanics or mechanics

 

 

 

 

without the proper tools and equipment

 

 

 

 

 

 

 

10

may not be able to properly perform the

 

 

SERVICING INFORMATION

services described in this manual.

 

 

 

 

 

 

Improper repair may result in injury to the

 

 

 

 

 

 

 

 

mechanic and may render the motorcycle

 

 

EMISSION CONTROL

11

unsafe for the rider and passenger.

 

 

INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRING DIAGRAM

12

 

 

 

 

 

© 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

Brake disc

 

E

2

Collar

 

3

Dust seal

 

4

Bearing

 

5

Spacer

 

L

6

Front axle

 

 

P

7

Front wheel

 

A Front axle bolt

M

B

Brake disc bolt

A

 

 

 

 

ITEM N·m kgf-m lb-ftS

A

100

10.0

72.5

B

23

2.3

16.5

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

SYMBOL

DEFINITION

Torque control required.

Data beside it indicates specified

Apply THREAD LOCK SUPER “1360”.

torque.

99000-32130

Apply oil. Use engine oil unless other-

Use engine coolant.

wise specified.

99000-99032-11X (Except USA)

Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI

Use fork oil.

MOLY PASTE in a ratio of 1:1)

99000-99001-SS5

Apply SUZUKI SUPER GREASE “A”

 

 

or equivalent grease.

 

 

Apply or use brake fluid.

99000-25010

 

 

 

E

 

 

 

 

 

Apply SUZUKI MOLY PASTE.

 

L

99000-25140

 

 

 

Measure in voltage range.

 

 

P

 

 

 

 

 

 

 

M

 

Apply SUZUKI BOND “1215”

 

 

or equivalent bond.

 

 

Measure in current range.

99000-31110

 

 

 

 

 

 

 

 

 

Apply

SUZUKI

 

 

 

 

BONDA“1207B”.

 

Measure in resistance range.

99104-31140 (U A)

 

 

 

 

 

 

 

 

Apply SUZUKI BOND “1207B”.

 

Measure in diode test range.

99000-31140 (Except USA)

 

 

 

 

 

Apply THREAD LOCK SUPER “1303”.

Measure in continuity test range.

99000-32030

 

 

 

 

 

 

 

Apply THREAD LOCK SUPER “1322”

or equivalent thread lock. Use special tool. 99000-32110

Apply THREAD LOCK “1342”.

Indication of service data.

99000-32050

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