- •HOW TO USE THIS MANUAL
- •TO LOCATE WHAT YOU ARE LOOKING FOR:
- •COMPONENT PARTS AND WORK TO BE DONE
- •SYMBOL
- •ABBREVIATIONS USED IN THIS MANUAL
- •01 GENERAL INFORMATION
- •COUNTRY AND AREA CODES
- •WARNING/CAUTION/NOTE
- •GENERAL PRECAUTIONS
- •SUZUKI GSX-R600K6 (’06-MODEL)
- •SERIAL NUMBER LOCATION
- •FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
- •BREAK-IN PROCEDURES
- •CYLINDER IDENTIFICATION
- •INFORMATION LABELS
- •SPECIFICATIONS
- •02 PERIODIC MAINTENANCE
- •PERIODIC MAINTENANCE SCHEDULE
- •MAINTENANCE AND TUNE-UP PROCEDURES
- •COMPRESSION PRESSURE CHECK
- •SDS CHECK
- •03 ENGINE
- •ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
- •ENGINE REMOVAL AND INSTALLATION
- •ENGINE DISASSEMBLY
- •ENGINE REASSEMBLY
- •04 FI SYSTEM DIAGNOSIS
- •PRECAUTIONS IN SERVICING
- •FI SYSTEM TECHNICAL FEATURES
- •ECM TERMINAL
- •SELF-DIAGNOSIS FUNCTION
- •FAIL-SAFE FUNCTION
- •FI SYSTEM TROUBLESHOOTING
- •SENSORS
- •05 FUEL SYSTEM AND THROTTLE BODY
- •FUEL DELIVERY SYSTEM
- •FUEL SYSTEM
- •THROTTLE BODY
- •06 EXHAUST SYSTEM
- •EXHAUST SYSTEM
- •EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)
- •07 COOLING AND LUBRICATION SYSTEM
- •ENGINE COOLANT
- •COOLING CIRCUIT
- •COOLING FAN
- •ECT SENSOR
- •THERMOSTAT
- •WATER PUMP
- •LUBRICATION SYSTEM
- •08 CHASSIS
- •EXTERIOR PARTS
- •FRONT WHEEL
- •FRONT FORK
- •STEERING DAMPER
- •STEERING
- •HANDLEBARS
- •REAR WHEEL
- •REAR SHOCK ABSORBER
- •REAR SUSPENSION
- •FRONT BRAKE
- •REAR BRAKE
- •TIRE AND WHEEL
- •DRIVE CHAIN
- •09 ELECTRICAL SYSTEM
- •CAUTIONS IN SERVICING
- •LOCATION OF ELECTRICAL COMPONENTS
- •CHARGING SYSTEM
- •STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
- •IGNITION SYSTEM
- •COMBINATION METER
- •LAMPS
- •RELAYS
- •BATTERY
- •10 SERVICING INFORMATION
- •TROUBLESHOOTING
- •WIRING HARNESS, CABLE AND HOSE ROUTING
- •TIGHTENING TORQUE
- •SERVICE DATA
- •11 EMISSION CONTROL INFORMATION
- •EMISSION CONTROL SYSTEMS
- •PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION
- •PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
- •HO2 SENSOR INSPECTION (For E-02, 19)
- •12 WIRING DIAGRAM
9-6 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
E
L
P
M
A
S
1 Fuel pump relay ( 5-7) |
9 Fuel pump ( 5-8) |
2 IAT sensor ( 4-53) |
0 Regulator/Rectifier |
3 Cooling fan relay ( 7-7) |
A Oil pressure switch |
4 PAIR control solenoid valve ( 11-7) |
B Generator |
5 CMP sensor ( 4-33) |
C Speed sensor |
6 Ignition coil (No.1, 2, 3, 4) |
D GP switch |
7 Horn |
E Side-stand switch |
8 Fuel level gauge |
F TO sensor ( 4-63) |
ELECTRICAL SYSTEM 9-7
E |
L |
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M |
A |
S |
1 Battery |
0 STP sensor ( 4-70) |
2 AP sensor ( 4-57) |
A TP sensor ( 4-44) |
3 Mode selection switch coupler ( 4-18) |
B IAP sensor ( 4-38) |
4 Fuse Box |
C Starter relay/Main fuse |
5 ECM (Engine Control Module) |
D Turn signal/Side-stand relay |
6 Secondary fuel injector ( 4-80) |
E EXCVA ( 6-4) |
7 Primary fuel injector ( 4-77) |
F CKP sensor ( 4-35) |
8 ECT sensor ( 4-49) |
G HO2 sensor (E-02, 19) ( 4-87) |
9 STV actuator ( 4-67) |
H Cooling fan ( 7-6) |
9-8 ELECTRICAL SYSTEM
CHARGING SYSTEM
Regulator/Rectifier
IG. switch
Generator
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Battery |
Load |
SCR |
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TROUBLESHOOTING |
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Battery runs down quickly |
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Step 1 |
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1) Check accessories which use excessive amounts of electricity. |
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Are accessories being installed? |
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YES |
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Remove accessories. |
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NO |
Go to tep 2. |
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Step 2 |
S |
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1) Check the battery for current leaks. ( 9-9) |
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Is the battery for current leaks OK? |
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YES |
Go to Step 3. |
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NO |
• Short circuit of wire harness |
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• Faulty electrical equipment |
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Step 3
1)Measure the regulated voltage between the battery terminals. ( 9-10) Is the regulated voltage OK?
YES |
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Faulty battery |
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Abnormal driving condition |
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NO |
Go to Step 4. |
Step 4
1)Measure the resistance of the generator coil. ( 9-10) Is the resistance of generator coil OK?
YES |
Go to Step 5. |
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NO |
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Faulty generator coil |
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Disconnected lead wires |
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ELECTRICAL SYSTEM 9-9
Step 5
1)Measure the generator no-load performance. ( 9-11) Is the generator no-load performance OK?
YES |
Go to Step 6. |
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NO |
Faulty generator |
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Step 6
1)Inspect the regulator/rectifier. ( 9-11) Is the regulator/rectifier OK?
YES
NO
Step 7
1)Inspect wirings. Is the wirings OK?
YES |
Faulty battery |
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NO |
• Short circuit of wire harness |
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• Poor contact of couplers |
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Battery overcharges |
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E |
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• Faulty regulator/rectifier |
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• Faulty battery |
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• Poor contact of generator lead wire coupler |
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INSPECTION |
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BATTERY CURRENT LEAKAGE |
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• Remove the front seat. ( A8-7) |
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S |
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• Turn the ignition switch to the OFF position. |
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• Disconnect the battery - lead wire. |
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• Measure the current between - battery terminal and the - |
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battery lead wire using the multi-circuit tester. If the reading |
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exceeds the specified value, leakage is evident. |
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09900-25008: Multi-circuit tester set |
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Battery current (leak): Under 3 mA |
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A |
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Tester knob indication: Current ( , 20 mA) |
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*In case of a large current leak, turn the tester to high range first to avoid tester damage.
*Do not turn the ignition switch to the “ON” position when measuring current.
9-10 ELECTRICAL SYSTEM
REGULATED VOLTAGE
• Remove the front seat. ( 8-7) |
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• Start the engine and keep it running at 5 000 r/min with the |
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dimmer switch turned HI position. |
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• Measure the DC voltage between the + and - battery termi- |
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nals using the multi-circuit tester. If the voltage is not within |
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the specified value, inspect the generator and regulator/recti- |
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fier. ( 9-10 and -11) |
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NOTE: |
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When making this test, be sure that the battery is in fully-charged |
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condition. |
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Battery |
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09900-25008: Multi-circuit tester set |
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Tester knob indication: Voltage ( ) |
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Regulated voltage (Charging output): |
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DCV |
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14.0 – 15.5 V at 5 000 r/min |
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GENERATOR COIL RESISTANCE |
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• Lift and support the fuel tank. ( 5-3) |
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• Disconnect the generator coupler. |
M |
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• Measure the resistance between the three lead wires. |
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If the resistance is out of specified value, replace the stator |
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with a new one. Also, check that the generator core is insulated properly.
09900-25008: Multi-circuitStester set
Tester knob indication: Resistance (Ω)
Generator coil resistance: 0.2 – 1.0 Ω (Yellow – Yellow)
∞Ω (Yellow – Ground)
NOTE:
When making above test, it is not necessary to remove the generator.
Y
Y
Y
ELECTRICAL SYSTEM 9-11
GENERATOR NO-LOAD PERFORMANCE |
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Lift and support the fuel tank. ( 5-3) |
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• Disconnect the generator coupler. |
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Y |
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• Start the engine and keep it running at 5 000 r/min. |
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• Using the multi-circuit tester, measure the voltage between |
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Y |
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three lead wires. |
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Y |
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If the tester reads under the specified value, replace the gen- |
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erator with a new one. |
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09900-25008: Multi-circuit tester set |
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Tester knob indication: Voltage (~) |
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Generator no-load performance: |
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65 V and more at 5 000 r/min (When engine is cold) |
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REGULATOR/RECTIFIER |
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• |
Lift and support the fuel tank. ( 5-3) |
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• Remove the air cleaner box. ( 5-14) |
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Disconnect the regulator/rectifier couplers. |
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E |
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• Measure the voltage between the lead wires using the multi |
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circuit tester as indicated in the table below. If the voltage is |
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not within the specified value, replace the regulator/rectifier |
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with a new one. |
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09900-25008: Multi-circuit tester set |
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Tester knob indication: Diode testM( ) |
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B/R1 |
B/W1 |
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B/R2 |
B/W2 |
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A |
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Unit: V |
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+ Probe of tester to: |
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B2 |
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to: |
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S |
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B1 |
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tester |
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B3 |
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- Probe of |
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more (tester’s battery voltage)
NOTE:
If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.