SUZUKI GSX-R 600 User Manual
GSX-R600
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 modifi-
cations 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.
!
WARNING
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 2008
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Service Data........................................................... 0C-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ...........1A-1
Emission Control Devices ...................................... 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System....................................................... 1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension....................................................2C-1
Wheels and Tires ...................................................2D-1
00
0
1
2
3
4
5
6
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Chain / Drive Train / Drive Shaft ................... 3A-1
Brake ........................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis ....................4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ...........................................................4C-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Manual Transmission ............................................. 5B-1
Clutch .....................................................................5C-1
Steering....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering / Handlebar .............................................. 6B-1
Body and Accessories............................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems.................................................... 9B-1
Combination Meter / Fuel Meter / Horn..................9C-1
Exterior Parts .........................................................9D-1
Body Structure ....................................................... 9E-1
9
Section 00
Precautions
CONTENTS
Table of Contents 00- i
00
Precautions ...............................................00-1
Precautions........................................................... 00-1
Warning / Caution / Note..................................... 00-1
General Precautions ........................................... 00-1
Precautions for Electrical Circuit Service ............ 00-2
00-1 Precautions:
Precautions
Precautions
Precautions
Warning / Caution / Note
B837H10000001
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.
!
WARNING
Indicates a potential hazard that could result
in death or injury.
!
CAUTION
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
!
WARNING
• 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 well ventilated and that you
follow all of the material manufacturer’s
instructions.
• Never use gasoline as cleaning solvent.
B837H10000002
• 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.
!
CAUTION
• 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 then the
positive (+) cable.
• When reconnecting the battery, connect
the positive (+) cable first and then the
negative (–) cable, and replace the terminal
cover on the positive (+) terminal.
• When performing service to electrical
parts, if the service procedures do not
require use of battery power, disconnect
the negative (–) cable the battery.
• When tightening the cylinder head or case
bolts and nuts, tighten the larger sizes
first. Always tighten the bolts and nuts
diagonally from the inside toward outside
and to the specified tightening torque.
• Whenever you remove oil seals, gaskets,
packing, O-rings, locking washers, selflocking nuts, cotter pins, circlips and
certain other parts as specified, be sure to
replace them with new ones. Also, before
installing these new parts, be sure to
remove any left over material from the
mating surfaces.
Precautions: 00-2
• Never reuse a circlip. When installing a
new circlip, take care not to expand the
end gap larger than required to slip the
circlip over the shaft. After installing a
circlip, always ensure that it is completely
seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners
to the specified torque. Wipe off grease
and oil if a thread is smeared with them.
• After reassembling, check parts for
tightness and proper operation.
• To protect the environment, do not
unlawfully dispose of used motor oil,
engine coolant and other fluids: batteries,
and tires.
• To protect Earth’s natural resources,
properly dispose of used motorcycle and
parts.
Precautions for Electrical Circuit Service
B837H10000003
When handling the electrical parts or servicing FI
system, observe the following points for the safety of the
systems.
• Inspect each terminal for corrosion and
contamination. The terminals must be clean and free
of any foreign material which could impede proper
terminal contact.
• Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.
I310G1000002-01
• Inspect each lead wire circuit for poor connection by
shaking it by hand lightly. If any abnormal condition is
found, repair or replace.
Electrical Parts
Connector / Coupler
• Faulty FI system is often related to poor electrical
contact of connector/coupler. Before servicing
individual electronic part, check electrical contact of
the connector/coupler.
• When connecting a connector, be sure to push it in
until a click is felt.
I823H1000002-01
• With a lock type coupler, be sure to release the lock
when disconnecting, and push it in fully to engage the
lock when connecting.
• When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires.
• Inspect each terminal on the connector/coupler for
looseness or bending.
• Push in the coupler straightly. An angled or skewed
insertion may cause the terminal to be deformed,
possibly resulting in poor electrical contact.
I310G1000003-02
• When taking measurements at electrical connectors
using a tester probe, be sure to insert the probe from
the wire harness side (rear) of the connector/coupler.
2
1
I649G1000013-02
1. Coupler 2. Probe
00-3 Precautions:
• When connecting meter probe from the terminal side
of the coupler (where connection from harness side
not being possible), use extra care not to force and
cause the male terminal to bend or the female
terminal to open. Connect the probe as shown to
avoid opening of female terminal. Never push in the
probe where male terminal is supposed to fit.
• Check the male connector for bend and female
connector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust, etc.
4
“A”
3
4
I649G1000030-02
3. Coupler 4. Probe “A”: Where male terminal fits
• Avoid applying grease or other similar material to
connector/coupler terminals to prevent electric
trouble.
Fuse
• When a fuse is blown, always investigate the cause to
correct it and then replace the fuse.
• Do not use a fuse of different capacity.
• Do not use wire or any other substitute for the fuse.
I649G1000001-02
Switch
Never apply grease material to switch contact points to
prevent damage.
ECM / Various sensors
• Since each component is a high-precision part, great
care should be taken not to apply any severe impacts
during removal and installation.
Clamp
• Clamp the wire harness at such positions as indicated
in “Wiring Harness Routing Diagram in Section 9A
(Page 9A-5)”.
• Bend the clamp properly so that the wire harness is
clamped securely.
• In clamping the wire harness, use care not to allow it
to hang down.
• Do not use wire or any other substitute for the band
type clamp.
CORRECT INCORRECT
I718H1000001-02
I310G1000007-01
• Be careful not to touch the electrical terminals of the
electronic parts (ECM, etc.). The static electricity from
your body may damage them.
I310G1000008-01
Precautions: 00-4
• When disconnecting and connecting the coupler,
make sure to turn OFF the ignition switch, or
electronic parts may get damaged.
1
I837H1000001-01
1. Ignition switch
Battery
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the FI and ABS systems instantly
when reverse power is applied.
• Before measuring voltage at each terminal, check to
make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis.
I310G1000012-02
• Never connect any tester (voltmeter, ohmmeter, or
whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit
may result.
• Never connect an ohmmeter to the electronic unit with
its coupler connected. If attempted, damage to ECM
or sensors may result.
• Be sure to use a specified voltmeter/ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
I718H1000004-01
• Removing any battery terminal of a running engine is
strictly prohibited. The moment such removal is made,
damaging counter electromotive force will be applied
to the electronic unit which may result in serious
damage.
Electrical Circuit Inspection Procedure
While there are various methods for electrical circuit
inspection, described here is a general method to check
for open and short circuit using an ohmmeter and a
voltmeter.
Open circuit check
Possible causes for the open circuit are as follows. As
the cause can exist in the connector/coupler or terminal,
they need to be checked carefully.
• Loose connection of connector/coupler.
• Poor contact of terminal (due to dirt, corrosion or rust,
poor contact tension, entry of foreign object etc.).
• Wire harness being open.
• Poor terminal-to-wire connection.
When checking system circuits including an electronic
control unit such as ECM, ABS control unit/HU, etc., it is
important to perform careful check, starting with items
which are easier to check.
1) Disconnect the negative (–) cable from the battery.
I310G1000011-01
00-5 Precautions:
2) Check each connector/coupler at both ends of the
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped.
“A”
“A”
1
1. Sensor “A”: Check for loose connection
ECM
I718H1000005-02
3) Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact
(possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact to
increase tension or replace. The terminals must be
clean and free of any foreign material which could
impede proper terminal contact.
Continuity check
1) Measure resistance across coupler “B” (between “A”
and “C” in figure).
If no continuity is indicated (infinity or over limit), the
circuit is open between terminals “A” and “C”.
“A”
“B”
ECM
“C”
I705H1000006-02
2) Disconnect the coupler “B” and measure resistance
between couplers “A” and “B-1”.
If no continuity is indicated, the circuit is open
between couplers “A” and “B-1”. If continuity is
indicated, there is an open circuit between couplers
“B-2” and “C” or an abnormality in coupler “B-2” or
coupler “C”.
“A”
“B-2”
ECM
“B”
“C”
I649G1000027-02
“B”: Check contact tension by inserting and removing.
“C”: Check each terminal for bend and proper alignment.
4) Using continuity inspect or voltage check procedure
as described below, inspect the wire harness
terminals for open circuit and poor connection.
Locate abnormality, if any.
“D”
”D”: Looseness of crimping
“E”: Open
“F”: Thin wire (A few strands left)
“F”
“E”
I649G1000028-02
“B”
“B-1”
“C”
I705H1000010-02
Voltage check
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors/couplers connected and voltage
applied to the circuit being checked, measure
voltage between each terminal and body ground.
2) If measurements were taken as shown in the figure
and results were listed in the following, it means that
the circuit is open between terminals “A” and “B”.
Voltage between
“A” and body ground: Approx. 5 V
“B” and body ground: Approx. 5 V
“C” and body ground: 0 V
Precautions: 00-6
3) Also, if measured values are as listed following, a
resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals “A” and
“B”.
Voltage between
“A” and body ground: Approx. 5 V
“B” and body ground: Approx. 5 V – 2 V voltage
drop
“C” and body ground: 3 V – 2 V voltage drop
“A”
ECM
“B”
“C”
Short circuit check (Wire harness to ground)
1) Disconnect the negative (–) cable from the battery.
2) Disconnect the connectors/couplers at both ends of
the circuit to be checked.
NOTE
If the circuit to be checked branches to other
parts as shown, disconnect all connectors/
couplers of those parts. Otherwise, diagnosis
will be wrong.
3) Measure resistance between terminal at one end of
circuit (“A” terminal in figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals “A” and “C”.
“A”
“D”
“B”
ECM
“C”
5V
0V
“A” “B” “C”
5V
5V
I705H1000007-01
“E”
5V
“A” “C”
I705H1000008-01
“D”: To other parts “E”: Other parts
00-7 Precautions:
4) Disconnect the connector/coupler included in circuit
(coupler “B”) and measure resistance between
terminal “A” and body ground. If continuity is
indicated, the circuit is shorted to ground between
terminals “A” and “B”.
“A”
“D”
ECM
“B”
“D”: To other parts
“C”
I705H1000009-02
Using The Multi-Circuit Testers
• Use the Suzuki multi-circuit tester set.
• Use well-charged batteries in the tester.
• Be sure to set the tester to the correct testing range.
Using the testers
• Incorrectly connecting the (+) and (–) probes may
cause the inside of the tester to be burned.
• If the voltage and current are not known, make
measurements using the highest range.
• When measuring the resistance with the multi-circuit
tester (1), ∞ will be shown as 10.00 MΩ and “1”
flashes in the display.
• Check that no voltage is applied before making the
measurement. If voltage is applied the tester may be
damaged.
• After using the tester, turn the power off.
Special tool
: 09900–25008 (Multi-circuit tester set)
Special tool
(A): 09900–25008 (Multi-circuit tester set)
(A)
I649G1000024-03
I649G1000002-02
NOTE
• When connecting the multi-circuit tester,
use the needle pointed probe to the back
side of the lead wire coupler and connect
the probes of tester to them.
• Use the needle pointed probe to prevent
the rubber of the water proof coupler from
damage.
• When using the multi-circuit tester, do not
strongly touch the terminal of the ECM
coupler with a needle pointed tester probe
to prevent terminal damage.
Special tool
(A): 09900–25009 (Needle pointed probe set)
(A)
I649G1000025-03
Section 0
General Information
CONTENTS
Table of Contents 0- i
0
General Information ................................ 0A-1
General Description .............................................0A-1
Symbols .............................................................. 0A-1
Abbreviations ...................................................... 0A-1
Vehicle Side View ............................................... 0A-2
Vehicle Identification Number ............................. 0A-3
Fuel and Oil Recommendation ........................... 0A-3
Engine Coolant Recommendation ...................... 0A-4
BREAK-IN Procedures........................................ 0A-4
Cylinder Identification.......................................... 0A-4
Country and Area Codes .................................... 0A-5
Wire Color Symbols ............................................ 0A-5
Warning, Caution and Information Labels
Location ............................................................ 0A-6
Component Location ...........................................0A-7
Electrical Components Location ......................... 0A-7
Specifications.......................................................0A-9
Specifications ...................................................... 0A-9
Special Tools and Equipment ........................... 0A-11
Special Tool ...................................................... 0A-11
Maintenance and Lubrication................. 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance ..............................0B-1
General Description .............................................0B-1
Recommended Fluids and Lubricants................. 0B-1
Scheduled Maintenance ......................................0B-1
Periodic Maintenance Schedule Chart................ 0B-1
Lubrication Points ............................................... 0B-2
Repair Instructions ..............................................0B-3
Air Cleaner Element Replacement...................... 0B-3
Air Cleaner Element Inspection .......................... 0B-3
Exhaust Pipe Bolt and Muffler Bolt Inspection ....0B-3
Exhaust Control Valve Inspection ....................... 0B-4
Valve Clearance Inspection and Adjustment ......0B-4
Spark Plug Replacement .................................... 0B-9
Spark Plug Inspection and Cleaning ...................0B-9
Fuel Line Inspection ..........................................0B-10
Evaporative Emission Control System
Inspection (E-33 only) ..................................... 0B-10
Engine Oil and Filter Replacement ...................0B-10
Throttle Cable Play Inspection and
Adjustment ......................................................0B-12
PAIR System Inspection ...................................0B-12
Throttle Valve Synchronization .........................0B-12
Cooling System Inspection................................0B-12
Clutch Cable Play Inspection and Adjustment ..0B-14
Drive Chain Inspection and Adjustment ............0B-15
Drive Chain Cleaning and Lubricating...............0B-16
Brake System Inspection .................................. 0B-17
Tire Inspection................................................... 0B-19
Steering System Inspection .............................. 0B-19
Front Fork Inspection ........................................ 0B-20
Rear Suspension Inspection .............................0B-20
Chassis Bolt and Nut Inspection ....................... 0B-20
Compression Pressure Check .......................... 0B-22
Oil Pressure Check ...........................................0B-22
SDS Check........................................................0B-22
Specifications.....................................................0B-22
Tightening Torque Specifications...................... 0B-22
Special Tools and Equipment ...........................0B-23
Recommended Service Material .......................0B-23
Special Tool ......................................................0B-23
Service Data ............................................. 0C-1
Specifications.......................................................0C-1
Service Data........................................................0C-1
Tightening Torque List ........................................0C-9
0A-1 General Information:
General Information
General Information
General Description
Symbols
B837H10101001
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 indicate specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1).
Apply SUZUKI SUPER GREASE “A” or equivalent.
99000-25010
Apply SUZUKI MOLY PASTE or equivalent.
99000-25140
Apply SUZUKI SILICONE GREASE or equivalent.
99000-25100
Apply SUZUKI BOND “1207B” or equivalent.
99000-31140
Apply THREAD LOCK SUPER “1303” or equivalent.
99000-32030
Apply THREAD LOCK SUPER “1322” or equivalent.
99000-32110
Apply THREAD LOCK SUPER “1360” or equivalent.
99000-32130
Use engine coolant or equivalent.
99000-99032-11X
Use fork oil or equivalent.
99000-99001-SS5
Apply MUFFLER SEAL LOCTITE “5920” (commercially available) or equivalent.
Apply or use brake fluid.
Use special tool.
Do not reuse.
Note on reassembly.
Abbreviations
B837H10101002
A:
ABDC: After Bottom Dead Center
AC: Alternating Current
ACL: Air Cleaner, Air Cleaner Box
API: American Petroleum Institute
ATDC: After Top Dead Center
ATM Pressure: Atmospheric Pressure, Atmospheric
Pressure Sensor (APS, AP Sensor)
A/F: Air Fuel Mixture
B:
BARO: Barometric pressure (Atmospheric pressure)
BBDC: Before Bottom Dead Center
BTDC: Before Top Dead Center
B+: Battery Positive Voltage
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
D:
DC: Direct Current
DMC: Dealer Mode Coupler
DOHC: Double Over Head Camshaft
DRL: Daytime Running Light
DTC: Diagnostic Trouble code
General Information: 0A-2
E:
ECM: 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
(EVAPC)
EXC System: Exhaust Control System (EXCS)
EXC Valve: Exhaust Control Valve (EXCV)
EXCV Actuator: Exhaust Control Valve Actuator
(EXCVA)
F:
FI: Fuel Injection, Fuel Injector
FP: Fuel pump
FPR: Fuel Pressure Regulator
FP Relay: Fuel Pump Relay
G:
GEN: Generator
GND: Ground
GP Switch: Gear Position Switch
H:
HC: Hydrocarbons
HO2 sensor: Heated Oxygen Sensor (HO2S)
I:
IAP Sensor: Intake Air Pressure Sensor (IAPS)
IAT Sensor: Intake Air Temperature Sensor (IATS)
IG: Ignition
ISC Valve: Idle Speed Control Valve (ISCV)
J:
JASO: Japanese Automobile Standards Organization
L:
LCD: Liquid Crystal Display
LED: Light Emitting Diode (Malfunction Indicator Lamp)
LH: Left Hand
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:
PAIR: Pulsed Secondary Air Injection
PCM: Power Control Module
PCV: Positive Crankcase Ventilation (Crankcase
Breather)
R:
RH: Right Hand
ROM: Read Only Memory
S:
SAE: Society of Automotive Engineers
SDS: Suzuki Diagnosis System
SRAD: Suzuki Ram Air Direct
STC 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)
T:
TO Sensor: Tip-over Sensor (TOS)
TP Sensor: Throttle Pos
ition Sensor (TPS)
Vehicle Side View
B837H10101003
NOTE
Difference between illustrations and actual
motorcycles may exist depending on the
markets.
SUZUKI GSX-R600 (2008-model)
Right Side
I837H1010001-01
Left Side
I837H1010002-01
0A-3 General Information:
Vehicle Identification Number
B837H10101004
The frame serial number or V.I.N. (Vehicle Identification
Number) “A” is stamped on the right side of the steering
head tube. The engine serial number “B” is located on
the lower crankcase. These numbers are required
especially for registering the machine and ordering
spare parts.
“A”
I837H1010003-02
Engine Oil (For USA)
Oil quality is a major contributor to your engine’s
performance and life. Always select good quality engine
oil.
Suzuki recommends the use of SUZUKI
PERFORMANCE 4 MOTOR OIL or equivalent engine
oil. Use of SF/SG or SH/SJ in API with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil.
If SAE 10W-40 engine oil is not available, select and
alternative according to the chart.
Engine Oil (For Other Countries)
Oil quality is a major contributor to your engine’s
performance and life. Always select good quality engine
oil. Use of SF/SG or SH/SJ in API with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil.
If SAE 10W-40 engine oil is not available, select an
alternative according to the chart.
“B”
I837H1010004-01
Fuel and Oil Recommendation
B837H10101005
Fuel (For USA and Canada)
Use only unleaded gasoline of at least 87 pump octane
(R/2 + M/2).
Gasoline containing MTBE (Meltyl 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 gasoline is recommended.
Brake Fluid
Specification and classification: DOT 4
!
WARNING
Since the brake system of this motorcycle is
filled with a glycol-based brake fluid by the
manufacturer, do not use or mix different
types of fluid such as silicone-based and
petroleum-based fluid for refilling the
system, otherwise serious damage will
result.
Do not use any brake fluid taken from old or
used or unsealed containers.
Never reuse brake fluid left over from a
previous servicing, which has been stored
for a long period.
Front Fork Oil
Use fork oil SS-05 or equivalent fork oil.
I310G1010005-01
General Information: 0A-4
Engine Coolant Recommendation
B837H10101006
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 perform as a corrosion and rust
inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the
atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT antifreeze/engine coolant. If this is not available, use an
equivalent which is compatible with an aluminum
radiator.
Liquid amount of water / Engine coolant
Solution capacity (total)
2 650 ml (2.8/2.3 US/Imp qt)
For engine coolant mixture information, refer to “Engine
Coolant Description in Section 1F (Page 1F-1)”.
!
CAUTION
Mixing of anti-freeze/engine coolant should
be limited to 60%. Mixing beyond it would
reduce its efficiency. If the anti-freeze/engine
coolant mixing ratio is below 50%, rust
inhabiting performance is greatly reduced.
Be sure to mix it above 50% even though the
atmospheric temperature does not go down
to the freezing point.
BREAK-IN Procedures
B837H10101007
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.
1) Keep to these break-in engine speed limits:
Speed limits
Initial 800 km (500 miles): Below 8 000 r/min
Up to 1 600 km (1 000 miles): Below 12 000 r/min
Over 1 600 km (1 000 miles): Below 16 000 r/min
2) Upon reaching an odometer reading of 1 600 km (1
000 miles) you can subject the motorcycle to full
throttle operation. However, do not exceed 16 000 r/
min at any time.
Cylinder Identification
B837H10101008
The four cylinders of this engine are identified as #1, 2, 3
and #4 cylinder, as counted from left to right (as viewed
by the rider on the seat).
#1
#2
#3
#4
I837H1010008-01
0A-5 General Information:
Country and Area Codes
The following codes stand for the applicable country(-ies) and area(-s).
Code Country or Area Effective Frame No.
GSX-R600 K8 (E-02) U.K. JS1CV111100100001 –
GSX-R600 K8 (E-19) E.U. JS1CV111100100001 –
GSX-R600U2 K8 (E-19) E.U. JS1CV211100100001 –
GSX-R600U3 K8 (E-19) E.U. JS1CV311100100001 –
GSX-R600 K8 (E-03) U.S.A (Except for California) JS1GN7EA 82100001 –
GSX-R600 K8 (E-24) Australia JS1CV111200100001 –
GSX-R600 K8 (E-28) Canada JS1GN7EA 82100001 –
GSX-R600 K8 (E-33) California (U.S.A) JS1GN7EA 82100001 –
Wire Color Symbols
Symbol Wire Color Symbol Wire Color
B Black G/W Green with White tracer
Bl Blue G/Y Green with Yellow tracer
Br Brown Gr/B Gray with Black tracer
Dbr Dark brown Gr/R Gray with Red tracer
Dg Dark green Gr/W Gray with White tracer
G Green Gr/Y Gray with Yellow tracer
Gr Gray Lg/Bl Light green with Blue tracer
Lbl Light blue Lg/G Light green with Green tracer
Lg Light green Lg/W Light green with White tracer
O Orange O/B Orange with Black tracer
P Pink O/Bl Orange with Blue tracer
R Red O/G Orange with Green tracer
W White O/R Orange with Red tracer
Y Yellow O/W Orange with White tracer
B/Bl Black with Blue tracer O/Y Orange with Yellow tracer
B/Br Black with Brown tracer P/B Pink with Black tracer
B/G Black with Green tracer P/W Pink with White tracer
B/Lg Black with Light green tracer R/B Red with Black tracer
B/O Black with Orange tracer R/Bl Red with Blue tracer
B/R Black with Red tracer R/Y Red with Yellow tracer
B/W Black with White tracer W/B White with Black tracer
B/Y Black with Yellow tracer W/Bl White with Blue tracer
Bl/B Blue with Black tracer W/G White with Green tracer
Bl/G Blue with Green tracer W/R White with Red tracer
Bl/W Blue with White tracer W/Y White with Yellow tracer
Bl/Y Blue with Yellow tracer Y/B Yellow with Black tracer
Br/B Brown with Black tracer Y/Bl Yellow with Blue tracer
Br/Y Brown with Yellow tracer Y/G Yellow with Green tracer
G/B Green with Black tracer Y/R Yellow with Red tracer
G/Bl Green with Blue tracer Y/W Yellow with White tracer
G/R Green with Red tracer
B837H10101009
B837H10101010
General Information: 0A-6
Warning, Caution and Information Labels Location
B837H10101011
7, 9
[A] [B]
1
2, 3
19, 21
4
6
18
[D] [E]
20
12, 13
1. Noise label (For E-03, 33) 15. General warning label (French) (For GSX-R600U2 E-19)
2. Noise label (For E-24) 16. General warning label (English/French) (For E-28)
3. Information label (For E-03, 28, 33) 17. General warning label (French/German/Italian/Swedish) (For E-19,
4. Vacuum hose routing label (For E-33) 18. ICES Canada label (For E-28)
5. Fuel caution label (For E-24) 19. I.D. plate (For E-02, 19, 24, GSX-R600U2 E-19, GSX-R600U3 E-19)
6. Manual notice label (For E-03, 33) 20. I.D. label (For GSX-R600U2 E-19)
7. Screen label (English) (For E-02, 03, 24, 28, 33) 21. Safety plate (For E-03, 28, 33)
8. Screen label (French) (For E-28) [A]: Frame (LH)
9. Screen label (French/German/Italian/Swedish) (For E-19, GSX-R600U2 E-19,
GSX-R600U3 E-19)
10. Steering warning label (English) (For E-03, 33) [C]: Intake cover
11. Steering warning label (French/German/English) (For E-02, 19, 24, 28, GSXR600U2 E-19, GSX-R600U3 E-19)
12. Tire information label (English) (For E-03, 33) [E]: Frame (RH)
13. Tire information label (French/German/English) (For E-02, 19, 24, 28, GSXR600U2 E-19, GSX-R600U3 E-19)
14. General warning label (English) (For E-02, 03, 24, 33)
[B]: Rear fender, front
[D]: Chain case
[C]
GSX-R600U3 E-19)
8
10, 11
14, 15, 16, 17
5
I837H1010005-01
0A-7 General Information:
Component Location
Electrical Components Location
1
4
5
2
3
11
B837H10103001
10
7
9
6
8
12
16
17
18
19
15
20
14
13
22
21
23
1. EXCV actuator 9. CMP sensor 17. Fuel pump relay
2. IAP sensor 10. PAIR control solenoid valve 18. Cooling fan relay
3. TP sensor 11. Starter relay/Main fuse 19. AP sensor
4. STP sensor 12. Drive mode selector 20. Battery
5. STV actuator 13. Fuse box 21. EVAP system purge control solenoid valve (E-33 only)
6. Fuel pump 14. ECM 22. CKP sensor
7. Fuel level gauge 15. TO sensor 23. HO2 sensor
8. Ignition coil 16. Mode select switch coupler 24. Cooling fan
24
I837H1010006-03
27
General Information: 0A-8
29
25
26
28
30
31
32
33
34
35
36
38
37
25. IAT sensor 31. Head light relay 37. Oil pressure switch
26. ISC valve 32. Turn signal/Side-stand relay 38. Generator
27. Secondary fuel injector 33. Steering damper solenoid valve 39. GP switch
28. Primary fuel injector 34. Horn 40. Speed sensor
29. Ignition switch 35. Regulator/Rectifier 41. Side-stand switch
30. ECT sensor 36. Starter motor
39
40
41
I837H1010007-03
0A-9 General Information:
Specifications
Specifications
NOTE
These specifications are subject to change without notice.
Dimensions and dry mass
Item Specification Remark
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)
Ground clearance 130 mm (5.1 in)
Seat height 810 mm (31.9 in)
Dry mass
Engine
Item Specification Remark
Type 4-stroke, Liquid-cooled, DOHC
Number of cylinders 4
Bore 67.0 mm (2.638 in)
Stroke 42.5 mm (1.673 in)
Displacement 599 cm
Compression ratio 12.8 : 1
Fuel system Fuel injection system
Air cleaner Paper element
Starter system Electric
Lubrication system Wet sump
Idle speed 1 300 ± 100 r/min
166 kg (365 lbs) E-33
165 kg (363 lbs) Others
3
(36.5 cu. in)
B837H10107001
Drive train
Item Specification Remark
Clutch Wet multi-plate type
Transmission 6-speed constant mesh
Gearshift pattern 1-down, 5-up
Primary reduction ratio 1.974 (77/39)
Low 2.785 (39/14)
2nd 2.052 (39/19)
Gear ratios
3rd 1.714 (36/21)
4th 1.500 (36/24)
5th 1.347 (31/23)
Top 1.208 (29/24)
Final reduction ratio 2.687 (43/16)
Drive chain RK 525SMOZ8, 114 links
General Information: 0A-10
Chassis
Item Specification Remark
Front suspension Inverted telescopic, coil spring, oil damped
Rear suspension Link type, coil spring, oil damped
Front suspension stroke 120 mm (4.7 in)
Rear wheel travel 130 mm (5.1 in)
Caster 23° 45’
Tail 97 mm (3.8 in)
Steering angle 27° (right & left)
Turning radius 3.4 m (11.2 ft)
Front brake Disc brake, twin
Rear brake Disc brake
Front tire size 120/70ZR17M/C (58W), tubeless
Rear tire size 180/55ZR17M/C (73W), tubeless
Electrical
Item Specification Remark
Ignition type Electronic ignition (Transistorized)
Ignition timing 6° B.T.D.C. at 1 300 r/min
Spark plug NGK CR9EIA-9 or DENSO IU27D
Battery 12 V 28.8 kC (8 Ah)/10 HR
Generator Three-phase A.C. generator
Main fuse 30 A
Fuse 15/10/15/15/10/10 A
Headlight
Position 12 V 5 W
Brake light/Taillight LED
License plate light 12 V 5 W
Turn signal light 12 V 21 W
Speedometer light LED
Tachometer light LED
Fuel level indicator light LED
Turn signal indicator light LED
Neutral indicator light LED
High beam indicator light LED
Oil pressure/Coolant temperature/
FI indicator light
Engine R.P.M. indicator light LED
Immobilizer indicator light LED E-02, 19, 24
High 12 V 60 W (HB3) x 2
Low 12 V 55 W (H11)
LED
Capacities
Item Specification Remark
Fuel tank
Oil change 2 200 ml (2.3/1.9 US/lmp qt)
Engine oil
Engine coolant 2.65 L (2.8/2.3 US/lmp qt)
With filter change 2 500 ml (2.6/2.2 US/lmp qt)
Overhaul 2 900 ml (3.1/2.6 US/lmp qt)
16 L (4.2/3.5 US/lmp gal) E-33
17 L (4.5/3.7 US/lmp gal) Others
0A-11 General Information:
Special Tools and Equipment
Special Tool
09900–06104
Snap ring pliers
09900–20202
Micrometer (1/100
mm, 25 – 50 mm)
09900–06107
Snap ring pliers
09900–20203
Micrometer (1/100
mm, 50 – 75 mm)
09900–06108
Snap ring pliers
09900–20205
Micrometer (0 – 25
mm)
09900–18740
Hexagon socket (24
mm)
09900–20530
Cylinder gauge set
B837H10108002
09900–20102
Vernier calipers (1/20
mm, 200 mm)
09900–20602
Dial gauge (1/1000
mm, 1 mm)
09900–20605
Dial calipers (1/100
mm, 10 – 34 mm)
09900–21304
V-block (100 mm)
09900–25008
Multi-circuit tester set
09900–20607
Dial gauge (1/100 mm,
10 mm)
09900–22301
Plastigauge (0.025 –
0.076 mm)
09900–25009
Needle pointed probe
set
09900–20701
Magnetic stand
09900–22302
Plastigauge (0.051 –
0.152 mm)
09900–28630
TPS test wire harness
09900–20803
Thickness gauge
09900–22401
Small bore gauge (10
– 18 mm)
09904–41010
SDS set
09900–20805
Tire depth gauge
09900–22403
Small bore gauge (18
– 35 mm)
09913–10750
Compression gauge
adapter
General Information: 0A-12
09913–50121
Oil seal remover
09915–74540
Oil pressure gauge
attachment
09916–33210
Valve guide reamer
(4.5 mm)
09913–70210
Bearing installer set
09915–77331
Meter (for high
pressure)
09916–33320
Valve guide reamer
(9.8 mm)
09915–40610
Oil filter wrench
09916–10911
Valve lapper set
09916–34542
Reamer handle
09915–64512
Compression gauge
09916–14510
Valve spring
compressor
09916–43211
Valve guide remover/
installer
09915–74521
Oil pressure gauge
hose
09916–14522
Valve s p r ing
compressor
attachment
09916–57370
Attachment
09916–77310
Piston ring
compressor
09921–20210
Bearing remover
09916–84511
Tweezers
09921–20240
Bearing remover set
09917–47011
Vacuum pump gauge
09922–22711
Drive chain cutting
and joining tool
09919–28620
Sleeve protector
09923–74511
Bearing remover
09920–53740
Clutch sleeve hub
holder
09924–84510
Bearing installer set
0A-13 General Information:
09924–84521
Bearing installer set
09930–11950
Torx wrench
09930–82720
Mode select switch
09925–18011
Steering bearing
installer
09930–30104
Rotor remover slide
shaft
09940–14911
Steering stem nut
wrench
09930–10121
Spark plug wrench set
09930–34980
Rotor remover
09940–14940
Swingarm pivot thrust
adjuster socket
wrench
09930–11920
Torx bit (JT40H)
09930–44520
Rotor holder
09940–14960
Steering nut wrench
socket
09930–11940
Bit holder
09930–44530
Rotor holder
09940–14980
Rotor remover
09940–30221
Front fork assembling
tool
09940–92720
Spring scale
09940–40211
Fuel pressure gauge
adapter
09940–94922
Front fork spring
stopper plate
09940–40220
Fuel pressure gauge
hose attachment
09940–94930
Front fork spacer
holder
09940–52841
Inner rod holder
09941–34513
Steering race installer
09940–52861
Front fork oil seal
installer
09943–74111
Fork oil level gauge
General Information: 0A-14
09944–28320
Hexagon socket (19
mm)
99565–01010–015
CD-ROM Ver.15
0B-1 Maintenance and Lubrication:
General Information
Maintenance and Lubrication
Precautions
Precautions for Maintenance
B837H10200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed
in terms of kilometers, miles and months for your convenience.
NOTE
More frequent servicing may be required on motorcycles that are used under severe conditions.
General Description
Recommended Fluids and Lubricants
Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)” and “Engine Coolant Recommendation in Section
0A (Page 0A-4)”.
B837H10201001
Scheduled Maintenance
Periodic Maintenance Schedule Chart
NOTE
I = Inspect and clean, adjust, replace or lubricate as necessary.
R = Replace.
T = Tighten.
Interval
Item
Air cleaner element — I I R I
Exhaust pipe bolts and muffler bolts T — T — T
Exhaust control valve I — I — I
Valve clearance ———— I
Spark plugs — I R I R
Fuel line —IIII
Evaporative emission control system
(E-33 only)
Engine oil RRRRR
Engine oil filter R — — R —
Throttle cable play IIIII
PAIR (air supply) system — — I — I
Throttle valve synchronization
Engine coolant Replace every 2 years.
Radiator hose —IIII
Clutch cable play —IIII
Drive chain
Brakes IIIII
Brake fluid
Brake hoses
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months2 12243648
—— I — I
I
(E-33 only)
—I—I
IIIII
Clean and lubricate every 1 000 km (600 miles).
—IIII
Replace every 2 years.
—IIII
Replace every 4 years.
B837H10205001
Maintenance and Lubrication: 0B-2
Interval
Item
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months2 12243648
Tires —IIII
Steering I—I—I
Front fork — — I — I
Rear suspension — — I — I
Chassis bolts and nuts TTTTT
Lubrication Points
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated as follows.
NOTE
• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the
motorcycle has been operated under wet or rainy conditions.
1
3
2
1. Clutch lever holder 5. Brake lever holder
2. Side stand pivot and spring hook 6. Brake pedal pivot and footrest pivot
3. Gearshift lever pivot and footrest pivot : Apply grease.
4. Drive chain : Apply oil.
4
6
5
B837H10205002
I837H1020001-01
0B-3 Maintenance and Lubrication:
FWD
Repair Instructions
Air Cleaner Element Replacement
B837H10206001
Replace air cleaner element
Every 18 000 km (11 000 miles, 36 months)
Refer to “Air Cleaner Element Removal and Installation
in Section 1D (Page 1D-6)”.
Air Cleaner Element Inspection
B837H10206002
Inspect air cleaner element
Every 6 000 km (4 000 miles, 12 months)
Inspection
1) Remove the air cleaner element. Refer to “Air
Cleaner Element Removal and Installation in Section
1D (Page 1D-6)”.
2) Inspect the air cleaner element for clogging. If it is
clogged with dirt, replace it with a new one.
!
CAUTION
Do not blow the air cleaner element with
compressed air.
NOTE
If driving under dusty conditions, replace the
air cleaner element more frequently. Make
sure that the air cleaner is in good condition
at all times. The life of the engine depends
largely on this component.
3) Drain water from the air cleaner box by removing the
drain plug (1).
1
I837H1020003-01
4) Reinstall the removed parts.
Exhaust Pipe Bolt and Muffler Bolt Inspection
B837H10206003
Tighten exhaust pipe bolts and muffler bolts
Initially at 1 000 km (600 miles, 2 months) and every
12 000 km (7 500 miles, 24 months) thereafter
Check the exhaust pipe bolts and muffler bolts to the
specified torque.
Tightening torque
Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Exhaust pipe mounting bolt (b): 23 N·m (2.3 kgf-m,
16.5 lb-ft)
Exhaust pipe bracket bolt (c): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Muffler connecting bolt (d): 23 N·m (2.3 kgf-m, 16.5
lb-ft)
Muffler cover bolt (e): 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)
Muffler mounting bolt (f): 25 N·m (2.5 kgf-m, 18.0 lbft)
I837H1020002-01
(a)
FWD
(f)
(e)
(d)
(c)
(b)
I837H1020004-03
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