Suzuki GSX-R600 Manual
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Suzuki GSX-R600 Manual

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California Proposition 65 Warning
Operating, servicing and maintaining a passenger
vehicle or off-road vehicle can expose you to
chemicals
monoxide, phthalates, and lead, which are known to
the State of California to cause cancer and birth
defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in
a well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For
more information go to www.P65Warnings.ca.gov/
passenger-vehicle.
This manual should be considered a permanent part of the
motorcycle and should remain with the motorcycle when resold
or otherwise transferred to a new owner or operator. The
manual contains important safety information and instructions
which should be read carefully before operating the motorcycle.
WARNING
including
engine
exhaust,
carbon

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Summary of Contents for Suzuki GSX-R600

  • Page 1 California Proposition 65 Warning WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 2 Therefore, please fol- low the maintenance instructions closely to ensure emission com- NOTICE pliance. Your Suzuki dealer has experienced technicians that are Indicates a potential hazard trained to provide your machine that could result in vehicle or with the best possible service with equipment damage.
  • Page 3 Suzuki reserves the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehi- cles previously built or sold.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS THE SPORT OF MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 6: The Sport Of Motorcycling

    THE SPORT OF MOTORCYCLING MOST ACCIDENTS CAN BE AVOIDED ............. 1-2 IF YOU DON’T HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE ..............1-2 IF A COLLISION IS IMMINENT, DO SOMETHING ..........1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......... 1-4 KNOW YOUR LIMITS ..................

  • Page 7: Most Accidents Can Be Avoided

    MOST ACCIDENTS CAN BE THE SPORT OF AVOIDED MOTORCYCLING The most common type of motor- cycle accident in the U.S. occurs Your motorcycle and this owner’s when a car traveling towards a manual have been designed by motorcycle turns left in front of the people like you who enjoy motor- motorcycle.

  • Page 8: If A Collision Is Imminent, Do Something

    Helmets do not reduce essential Experienced motorcyclists learn vision or hearing. Generally, hel- to “cover” the front brake lever by mets do not cause or intensify lightly resting a couple of fingers injury if you crash. Helmets simply over the lever when riding in traffic help your skull protect your intelli- and near intersections to give gence, your memory, your per-...

  • Page 9: Special Situations Require Special Care

    SPECIAL SITUATIONS REQUIRE KNOW YOUR LIMITS SPECIAL CARE Always ride within the boundaries of your own skills. Knowing these Of course, there are some times limits and staying within them will when full-force braking is not the help you avoid accidents. correct technique.

  • Page 10: Be Extra Safety-Conscious On Bad Weather Days

    BE EXTRA SAFETY-CONSCIOUS INSPECTION BEFORE RIDING ON BAD WEATHER DAYS Review the instructions in the “INSPECTION BEFORE RIDING” Riding on bad weather days, section of this manual. Perform an especially wet ones, requires entire pre-ride inspection before extra caution. Braking distances you head out on the road.

  • Page 11: Carrying A Passenger

    CARRYING A PASSENGER MOTORCYCLE SAFETY FOUNDATION’S Carrying a passenger, when done correctly, is a great way to share “RIDING TIPS AND PRACTICE the joy of motorcycling. You will GUIDE” HANDBOOK have to alter your riding style (FOR OWNERS IN USA) somewhat since the extra weight This special handbook, supplied of a passenger will affect handling...

  • Page 12: Conclusion

    Motorcycle Safety Foundation. Your Suzuki dealer can help you locate fundamental advanced riding skills course nearest you, or owners in the USA can call toll-free 1-800-446-9227.

  • Page 14: Fuel, Engine Oil And Coolant Recommendations

    FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL ........................2-2 ENGINE OIL ......................2-4 ENGINE COOLANT SOLUTION ................. 2-6...
  • Page 15 In such case, those recommended for gasoline. try changing to a different gas Use the recommended gasoline. station. If the situation is not improved by changing, consult your Suzuki dealer.
  • Page 16 NOTE: • To help minimize air pollution, Suzuki recommends that you use oxygenated fuels. • Be sure that any oxygenated fuel you use has octane rat- ings of at least 90 pump octane ((R+M)/2 method).
  • Page 17 ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of Suzuki recommends the use of SAE 10W-40 engine oil. If SAE SUZUKI PERFORMANCE 10W-40 engine oil is not available, MOTOR OIL or equivalent engine select an alternative according to oil.
  • Page 18 JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle or “RESOURCE CONSERVING” engines. Motorcycle and ATV oils. Some engine oils which have...
  • Page 19  WARNING mends the use of ECSTAR brand coolant. ECSTAR has been spe- Engine coolant is harmful or cially formulated for your SUZUKI fatal if swallowed or inhaled. product and contributes to the Solution can be poisonous to desired motorcycle performance and ideal riding experience.
  • Page 20 (Green) “SUZUKI SUPER LONG LIFE COOLANT” is pre-mixed to the Water for Mixing proper ratio. Add only “SUZUKI Use distilled water only. Water SUPER LONG LIFE COOLANT” other than distilled water can cor- if coolant level drops. It is not nec- rode and clog the aluminum radia- essary to dilute “SUZUKI SUPER...

  • Page 22: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 KEY ........................3-5 IGNITION SWITCH ....................3-5 INSTRUMENT PANEL ..................3-8 LEFT HANDLEBAR ................... 3-22 RIGHT HANDLEBAR ..................3-25 FUEL TANK CAP ....................3-28 GEARSHIFT LEVER ..................3-29 REAR BRAKE PEDAL ..................3-30 SEAT LOCK AND HELMET HOLDERS ............

  • Page 23: Location Of Parts

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS GSX-R600 1 Clutch lever 2 Left handlebar switches 3 Ignition switch 4 Instrument panel 5 Front brake fluid reservoir 6 Right handlebar switches 7 Throttle grip 8 Front brake lever 9 Fuel tank cap...
  • Page 24 GSX-R600 0 Battery A Fuses B Seat lock C Helmet holders D Tools E Gearshift lever F Side stand...
  • Page 25 GSX-R600 G Rear brake pedal...

  • Page 26: Key

    IGNITION SWITCH Two keys come with this motorcy- The ignition switch has 4 posi- cle. Keep the spare key in a safe tions: place. “OFF” position  WARNING All electrical circuits are cut off. The engine will not start. The key Due to the location of the steer- can be removed.
  • Page 27 “P” (PARKING) position Taillight will come on to increase visibility for temporary roadside parking at night. The key can be removed and the steering will be locked.  WARNING Turning the ignition switch to the “P” (PARKING) or “LOCK” “LOCK” position All electrical circuits are off.
  • Page 28 If the motorcycle falls down, turn the ignition switch off immediately. Ask your autho- rized Suzuki dealer to inspect the motorcycle for unseen damage. The key hole can be covered by turning the lid.

  • Page 29: Instrument Panel

    INSTRUMENT PANEL If the tachometer needle does not point to zero, follow the procedure below to reset the tachometer. 1. Press and hold the ADJ button 1 and turn on the ignition switch. 2. Hold the ADJ button 1 for 3 – 5 seconds.
  • Page 30 Tachometer 3 Speedometer 6 The tachometer indicates the The speedometer indicates the engine speed in revolutions per road speed in miles per hour or minute (r/min). kilometers per hour. Gear Position Indicator 4 NOTE: Set the meter display A to The gear position indicator indi- •...
  • Page 31 “Sd” and the red indicator light cates “FI” or “Sd” in the odometer comes on, have your autho- display area in following 2 modes; rized Suzuki dealer or a quali- fied mechanic inspect the A. The display A in the odometer electronic control system as display area alternately indi- soon as possible.
  • Page 32 Fuel Indicator Light “” 8 This indicator light comes on for 3 seconds when the ignition switch is turned to the “ON” position. When display indicates Then the indicator light should go “CHEC” in the odometer display out if there is enough fuel in the area check the following items;...
  • Page 33 Odometer METER METER Trip meter 1 Odometer/Trip Meter/ Reserve Trip Meter/Clock/ Instrument Panel Light Brightness/ Lap Time Counter A Trip meter 2 The display has 7 functions; odometer, 2 trip meters, reserve trip meter, clock, instrument panel light brightness and lap time counter.
  • Page 34 Odometer Reserve trip meter The odometer registers the total The reserve trip meter counts dis- distance that the motorcycle has tance from fuel tank reserve point been ridden. odometer until the fuel tank is refilled. The ranges from 0 to 999999. fuel level indicator starts blinking and the reserve trip meter starts NOTE: The odometer display...
  • Page 35 Instrument panel light brightness Pushing the ADJ button 1 will change the instrument panel light brightness in 5 steps. The bright- ness indicator indicates bright-  ness from “ ” (min)  “ ” (max). Lap time counter The lap time counter can counts 99 lap times and total time.
  • Page 36 2. To measure lap time METER METER 1.Press and hold the SEL but- ton B, METER or METER for more than 1 second. The display stops blinking. 1 Lap number 2 Lap time 3 Total time 3.When the METER pushed, the lap time counter records lap time data and the display shows lap number and then shows lap time for 4 sec-...
  • Page 37 METER METER 3. To check lap time memory data 2.Push METER or METER to increase or decrease lap number. 3.L – F indicates minimum lap time. 1.Press and hold the SEL but- ton B for more than 3 sec- onds. Display shows number and lap time alter-...
  • Page 38 00:00”00. indicator. While the coolant tem- perature is below 67°F, the display Suzuki Drive Mode Indicator C does not indicate a number but The Suzuki drive mode indicator indicates “– – –”. displays drive mode, A and B,...
  • Page 39 “” and the indicator light out, have your authorized should go out. Suzuki dealer or a qualified mechanic inspect your motor- cycle. 3-18...
  • Page 40 Engine Rpm Indicator E, F The engine rpm indicator LED’s will light or blink when the engine speed reaches a preset engine rpm. NOTE: Be sure to reset the engine rpm indicator in the instrument panel when the battery terminals are reconnected. Orange LED White LED LED1...
  • Page 41 Orange LED White LED LED1 LED2 LED3 1. White LED Lighting LIGHT BLINK NO LIGHT   Blink White LED –    Indicator mark – 1.Press and hold the SEL button B and turn on the ignition switch. Keep the SEL button B pressed for more than 2 seconds.
  • Page 42 2. White LED Brightness 1.Push the SEL button B from white LED lighting mode to change white LED brightness mode. 2.Push the ADJ button 1 to change brightness in 5 steps. The   brightness indicator changes from “ ” (min) to “ ”...

  • Page 43: Left Handlebar

    LEFT HANDLEBAR Headlight flasher switch Press the dimmer switch of “” position to flash the headlight high beam. NOTICE Sticking tape placing objects in front of the headlight can obstruct headlight heat radiation. This can result in headlight damage. Do not stick tape on the head- light or place objects in front of the headlight.
  • Page 44 Drive mode is preset at A-mode when the ignition switch and the engine stop switch are turned on. At this time, the Suzuki drive mode indicator shows nothing. Follow the procedure below to Throttle opening operate the Suzuki drive mode selector.
  • Page 45 Turn Signal Light Switch “” 6 Moving the switch to the “” position will flash the left turn sig- nals. Moving the switch to the “” position will flash the right turn signals. The indicator light will also flash intermittently. To cancel turn signal operation, push the switch in.

  • Page 46: Right Handlebar

    RIGHT HANDLEBAR Front Brake Lever Adjustment METER Engine Stop Switch 1 The distance between the throttle “” position grip and the front brake lever is The ignition circuit is off. The adjustable to 6 positions. To engine cannot start or run. change the position, push the brake lever forward and turn the “”...
  • Page 47 NOTICE Engaging the starter motor for more than five seconds at a time can damage the starter METER motor and wiring harness from overheating. Do not engage the starter Electric Starter Switch “” 3 motor for more than five sec- Use this switch to operate the onds at a time.
  • Page 48 • When the neutral indicator light goes off, the gear posi- tion indicator should indicate either “1”, “2”, “3”, “4”, “5” or “6”. • If the neutral indicator light and the gear position indica- tor are not working properly, consult your Suzuki dealer. 3-27...

  • Page 49: Fuel Tank Cap

    FUEL TANK CAP 1 Fuel level 2 Filler neck  WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. To open the fuel tank cap, insert Stop adding fuel when the fuel the ignition key into the lock and level reaches the bottom of the...

  • Page 50: Gearshift Lever

    GEARSHIFT LEVER  WARNING Failure to follow safety precau- tions when refueling could result in a fire or cause you to breathe toxic fumes. Refuel in a well ventilated area. Make sure the engine is off and avoid spilling fuel on a hot engine.

  • Page 51: Rear Brake Pedal

    REAR BRAKE PEDAL SEAT LOCK AND HELMET HOLDERS Front Seat To remove the front seat. Depressing the rear brake pedal will apply the rear disk brake. The brake light will be illuminated when the rear brake is operated. 1. Remove fasteners.
  • Page 52 Raise the front end of the seat and slide it forward. To reinstall the seat, slide the seat hooks into the seat hook retainers on the frame and tighten the bolts To reinstall the seat, slide the seat securely. hooks into the seat hook retainers and push down firmly until the ...

  • Page 53: Side Stand

    Helmet Holders SIDE STAND This motorcycle has helmet hold- An interlock system is provided to ers underneath the rear seat. cut off the ignition circuit when the Hook your helmet on the helmet side stand is down and the trans- holder and lock the seat.

  • Page 54: Suspension Adjustment

    SUSPENSION ADJUSTMENT  WARNING The standard settings for both the front and rear suspensions are Riding with the side stand selected to meet various riding incompletely retracted conditions such as low to high result in an accident when you motorcycle speed and light to turn left.
  • Page 55 FRONT SUSPENSION Damping Force Adjustment Spring Pre-load Adjustment The rebound and compression To set the spring pre-load adjuster damping force can be individually to the standard position, turn the adjusted by turning the respective adjuster 1 counterclockwise until adjusters. The rebound damping force adjuster 2 and compres- it stops and turn the adjuster sion damping force adjuster 3...
  • Page 56 However, Suzuki  WARNING recommends that this adjustment be done by your authorized Unequal suspension adjust- Suzuki dealer, since a special tool ment can cause poor handling is needed for this job. and instability. Adjust the right and left front forks to the same setting.
  • Page 57 To adjust the damping force, set more information. the adjuster to the standard set- ting first and then adjust the NOTE: Ask your Suzuki dealer to adjuster to the desired position. dispose of the rear suspension unit. To set the rebound damping force...
  • Page 58 Low stroke speed damping force adjuster 3 To adjust the damping force, turn the adjuster in fully and then turn it out. The fully turned-in position provides stiffest damping force and turning the adjuster out will soften the damping force. Count the number of turns from the fully turned-in position.

  • Page 59: Footrests And Gearshift Lever Position Change

    LEVER POSITION CHANGE 23 N·m (2.3 kgf-m, 16.5 lbf-ft) Right and left footrest position and gearshift lever position can be NOTE: Apply a drop of SUZUKI changed in three positions to sit in THREAD LOCK “1342” to the a comfortable position.
  • Page 60 3. Tighten the bolts to the speci- fied torque. Footrest bracket tightening torque: 23 N·m (2.3 kgf-m, 16.5 lbf-ft) NOTE: Apply a drop of SUZUKI THREAD LOCK “1342” to the footrest mounting bolts 1. 3-39...
  • Page 61 65 – 75 mm 5. Loosen the gearshift lever (2.6 – 3.0 in) pivot. 7. Loosen the lock nuts 3. Turn the rod 4 and adjust the gear- shift lever position. 8. Rotate the rod 4 to locate the gearshift lever 65 – 75 mm (2.6 –...

  • Page 62: Break-In And Inspection Before Riding

    BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-3...
  • Page 63 BREAK-IN AND Breaking in the New Tires New tires need proper break-in to INSPECTION BEFORE assure maximum performance, RIDING just as the engine does. Wear- in the tread surface by gradually BREAK-IN increasing your cornering lean The first 800 km (500 miles) is the angles over the first 160 km (100 most important in the life of your miles) before attempting maxi-...
  • Page 64 Observe Your Initial and INSPECTION BEFORE RIDING Most Critical Service  WARNING The initial service (break-in main- tenance) is the most important Failure to inspect your motor- service your motorcycle will cycle before riding and to prop- receive. During break-in opera- erly maintain your motorcycle tion, all of the engine components will have mated together and...
  • Page 65 Check the condition of the motor- Brakes • Proper pedal and lever cycle to help make sure that you ( 3-25, operation 3-30, 7-34) • Fluid level in the reservoir do not have mechanical problems to be above “LOWER” line or get stranded somewhere when •...

  • Page 66: Riding Tips

    RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF ....................5-4 USING THE TRANSMISSION ................5-5 RIDING ON HILLS ....................5-6 STOPPING AND PARKING ................5-7 CARRYING A PASSENGER ................5-8...

  • Page 67: Starting The Engine

    • If the neutral indicator light NOTE: The fuel supply system and the gear position indica- stops the engine when the motor- tor are not working properly, cycle is overturned. Turn off the consult your Suzuki dealer. ignition switch before restarting the engine.
  • Page 68 When the Engine is Cold or NOTICE Warm: Close the throttle completely and Leaving the engine running for push the electric starter switch. an extended period or keeping the throttle opened, without When a Cold or Warm Engine is traveling, in order to charge the Hard to Start: battery, etc., may cause the Open the throttle approximately 1/8...

  • Page 69: Starting Off

    STARTING OFF  WARNING  WARNING Sudden side winds, which can occur when being passed by Riding at excessive speeds larger vehicles, at tunnel exits increases your chances of los- or in hilly areas, can cause you ing control of the motorcycle, to lose control of the motorcy- which can result in an acci- cle.

  • Page 70: Using The Transmission

    USING THE TRANSMISSION  WARNING The transmission is provided to keep engine operating Downshifting when engine smoothly in its normal operating speed is too high can: speed range. The gear ratios • cause the rear wheel to skid have been carefully chosen to and lose traction due to meet the characteristics of the increased engine braking,...

  • Page 71: Riding On Hills

    RIDING ON HILLS NOTICE • When climbing steep hills, the motorcycle may begin to slow Revving the engine into the red down and show lack of power. zone can cause severe engine At this point you should shift to damage. a lower gear so that the engine will again be operating in its Never allow the engine to rev...

  • Page 72: Stopping And Parking

    STOPPING AND PARKING  WARNING 1. Twist the throttle grip away from yourself to close the Hard braking on wet, loose, throttle completely. rough, or other slippery sur- 2. Apply the front and rear brakes faces can cause wheel skid evenly and at the same time.

  • Page 73: Carrying A Passenger

    5. Park the motorcycle on a firm, CARRYING A PASSENGER flat surface where it will not fall Before you invite someone to be a over. passenger on your motorcycle, you need to be thoroughly familiar  CAUTION with motorcycle operation. Adjust tire pressures and suspension A hot muffler can cause severe according to the Tire Pressure...

  • Page 74: Accessory Use And Motorcycle Loading

    ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE ....................6-2 ACCESSORY INSTALLATION GUIDELINES ............ 6-2 LOADING LIMIT ....................6-3 LOADING GUIDELINES ..................6-4 MODIFICATION ....................6-4...

  • Page 75: Accessory Use

    It is not possible motorcycle and as near the for Suzuki to test each accessory center of gravity as is feasible. on the market or combinations of Check...

  • Page 76: Loading Limit

    • Accessories fitted to the han- LOADING LIMIT dlebars or the front fork area  WARNING can create serious stability problems. This extra weight will cause the motorcycle to be Overloading or improper load- less responsive to your steer- ing can cause loss of motorcy- ing control.

  • Page 77: Loading Guidelines

    Suzuki’s limited warranties may • Keep cargo weight low and as not cover damage caused by close to the center of the modifications that would change motorcycle as possible.
  • Page 78 This could result in an unsafe vehicle operat- ing condition and subsequent accident. Suzuki will not be responsible in any way for per- sonal injury or damage to the motorcycle caused by frame mod- ifications.

  • Page 80: Inspection And Maintenance

    INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ................7-2 TOOLS ......................... 7-6 STEERING DAMPER MAINTENANCE ............... 7-6 LUBRICATION POINTS ..................7-7 BATTERY ......................7-8 AIR CLEANER ....................7-10 SPARK PLUGS ....................7-14 ENGINE OIL ....................... 7-20 ENGINE IDLE SPEED INSPECTION ..............7-26 THROTTLE CABLE PLAY ................

  • Page 81: Maintenance Schedule

    (*). You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, ask your Suzuki dealer to do the maintenance.
  • Page 82 Breathing carbon monoxide can cause death or When replacing parts on your severe injury. vehicle, use only genuine Suzuki replacement parts or Never start the engine or let it their equivalent. run indoors or where there is little or no ventilation.
  • Page 83 * PAIR (air supply) system – – – * Throttle valve synchronization – – (CA. only) “SUZUKI SUPER LONG LIFE Replace every 4 years or 48000 km (29000 miles) COOLANT” (Blue) “SUZUKI LONG * Engine coolant LIFE COOLANT” ( 7-28)
  • Page 84 Interval months 1000 6000 12000 18000 24000 Element miles 4000 7500 11000 14500 * Brakes ( 7-34) – Brake hose ( 7-34) *Replace every 4 years – Brake fluid ( 7-35) *Replace every 2 years Tires ( 7-39) – * Steering –...

  • Page 85: Tools

    TOOLS STEERING DAMPER MAINTENANCE 1. Keep the steering damper shaft 1 clean at all times. 2. Wipe off any oil residue with a cloth. A tool kit is provided with your motorcycle. It is located under the rear seat. NOTE: •...

  • Page 86: Lubrication Points

    LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motor- cycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet it in the rain or after washing it.

  • Page 87: Battery

    • If you cannot charge the bat-  WARNING tery, consult your authorized Suzuki dealer. Wiping the battery with a dry cloth can cause a static elec-  WARNING tricity spark, which can start a fire.
  • Page 88 Battery Removal NOTICE To remove the battery, follow the procedure below: Reversing the battery lead 1. Place the motorcycle on the wires can damage the charging side stand. system and the battery. 2. Remove the front seat by refer- ring to the SEAT LOCK AND Always attach the red lead to HELMET HOLDERS section.

  • Page 89: Air Cleaner

    Never run the engine without tery, consult your Suzuki dealer. the air cleaner element in place. 7-10...
  • Page 90 4. Remove the prop stay 2 if the prop stay is equipped. NOTE: A prop stay is available at your Suzuki dealer. The prop stay part number is 44574-35F00. 7-11...
  • Page 91 5. Lift the front end of the fuel 6. Remove the air cleaner holder bolt 3. tank and prop it up as shown 7. Remove the 10 screws 4. above. Insert the crank end of 8. Remove the cover 5. the prop stay into the hole of the steering shaft.
  • Page 92 Installation Reinstall the air cleaner element in reverse order of removal. NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine. 10.Inspect the air cleaner element Replace the air cleaner element condition. Replace with a new one if it is torn.

  • Page 93: Spark Plugs

    Consult Suzuki dealer. your Suzuki dealer or a qualified mechanic if your plug insulator is NOTE: This motorcycle uses a not a light brown color. resistor-type spark plug to avoid...
  • Page 94 Spark Plug Removal 1. Lift the fuel tank and remove the air cleaner cover by refer- ring to the AIR CLEANER sec- tion. 4. Disconnect the coupler 5. 2. Remove the ECM 1 from the air cleaner box. Remove the bolts 2 and two funnels 3.
  • Page 95 NOTICE Dirt can damage the moving engine parts of your motorcy- cle if it enters an open spark plug hole. Cover the spark plug hole while the spark plug is out of 8. Pull off the ignition coils. the hole. NOTICE Spark Plug Inspection Improper removal of ignition...
  • Page 96 Installation Reinstall the air cleaner box and To install a spark plug, turn it in as fuel tank in the reverse order of far as possible with your fingers, removal. then tighten it with a wrench. NOTICE Improper installation of the spark plug can damage your motorcycle.
  • Page 97 Air Cleaner Box Installation 3. Install the air cleaner box in 1. Position the PAIR hose 1 by the following order. Fit the right the ignition coil 2 as shown side air inlet tube to the frame above. hole first, then fit the left side inlet tube.
  • Page 98 NOTE: A prop stay is available at your Suzuki dealer. The prop stay part number is 44574-35F00. 6. Remove the screw 5. Unhook the bosses 6 and remove the cover. 8. Hook the PAIR hose by the fuel tank prop stay and pull the hose out to the front-right direction.

  • Page 99: Engine Oil

    ENGINE OIL NOTICE Engine life depends on oil amount and quality. Daily oil level checks Operating the motorcycle with and periodic changes are two of too little or too much oil can the most important maintenance damage the engine. items to be performed. Place the motorcycle on level Engine Oil Level Check ground.
  • Page 100 Engine Oil and Filter Change  WARNING Change the engine oil and oil filter at the scheduled times. The Children and pets may be engine should always be warm harmed by swallowing new or when the oil is changed so the oil used oil.
  • Page 101 NOTICE Turning the engine while drain- ing the engine oil will cause oil film shortage and adversely affect the engine. Do not use the electric starter switch during engine replacement work. NOTE: • Recycle or properly dispose of used oil. •...
  • Page 102 7. Turn the oil filter 5 counter- 5. Remove the bolts. Unhook the hooks. Remove the left fairing clockwise and remove it with a Suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. 6. Release the hoses from the clamp.
  • Page 103 “cap type” filter wrench or on the oil filter. Use Be sure to use a genuine an oil filter wrench to tighten Suzuki oil filter or an equiva- the filter 2 turns or to specified lent one designed for your torque.
  • Page 104 23 N·m (2.3 kgf-m, 16.5 lbf-ft) NOTE: If you do not have a proper NOTE: About 2200 ml (2.3 US qt) oil filter wrench, have your Suzuki of oil will be required when chang- dealer perform this service. ing oil only.

  • Page 105: Engine Idle Speed Inspection

    1200 – 1400 r/min when the engine is warm. NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. 2.0 – 4.0 mm (0.08 – 0.16 in) To adjust the cable play: 1.

  • Page 106: Fuel Hose

    FUEL HOSE Throttle Cable Boots The throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the boots when wash- Inspect the fuel hose for damage ing. Wipe off dirt from the boots and fuel leakage.

  • Page 107: Clutch Adjustment

    CLUTCH ADJUSTMENT ENGINE COOLANT Clutch cable play should be 10 – Coolant level 15 mm (0.4 – 0.6 in) measured at the clutch lever end. Adjust clutch cable play according to the follow- ing procedure: Minor Adjustment 10 – 15 mm (0.4 –...
  • Page 108 3. Remove the bolts. Unhook the hooks. Remove the right fair- ing. 4. Remove the filler cap and add specified engine coolant through the filler hole until it reaches the “F” line. Refer to the FUEL, ENGINE OIL AND COOLANT RECOMMENDA- 2.

  • Page 109: Drive Chain

    Radiator Hose Inspection Inspect the radiator hoses for cracks, damage or engine coolant leakage. If any defects are found, ask your Suzuki dealer to replace the radiator hose with a new one. 7-30...
  • Page 110 Good Worn clip type chain. Ask an autho- rized Suzuki dealer or a quali- fied mechanic to perform this work. Damage to the drive chain means that the sprockets may also be damaged. Inspect the sprockets for the following: •...
  • Page 111 Drive Chain Cleaning and NOTICE Oiling 1. Remove dirt and dust from the Some drive chain lubricant drive chain. Be careful not to contains solvents and addi- damage the seal ring. tives which could damage the 2. Clean the drive chain with a seal rings in the drive chain.
  • Page 112 Drive Chain Adjustment To adjust the drive chain, follow the procedure below:  CAUTION A hot muffler can burn you. The muffler will be hot enough to 20 – 30 mm burn you for some time after (0.8 – 1.2 in) stopping the engine.

  • Page 113: Brakes

    MAINTENANCE SCHEDULE. Brake Hose Inspection Inspect the brake hoses and hose joints for cracks, damage or brake fluid leakage. If any defects are found, ask your Suzuki dealer to replace the brake hose with a new one. 7-34...
  • Page 114 Brake Fluid  WARNING Brake fluid will gradually absorb moisture through the brake hoses. Brake fluid with high water content lowers the boiling point and can cause brake system malfunction due to corrosion of brake compo- nents. Boiling brake fluid or FRONT brake system...
  • Page 115 Be careful not to spill any fluid when filling the brake fluid res- ervoir. Wipe spilled fluid up immediately. FRONT REAR NOTE: SUZUKI highly recom- mends the use of ECSTAR brand brake fluid. ECSTAR has been specially formulated your SUZUKI product and contributes...
  • Page 116 NOTE: Do not squeeze/depress If you need to replace brake the brake lever/pedal when the pads, have your Suzuki dealer pads are not in their positions. It is do this work. Inspect and main- difficult to push the pistons back...
  • Page 117 Rear Brake Pedal Adjustment Rear Brake Light Switch The rear brake pedal position must be properly adjusted at all times or the disk brake pads will rub against the disk causing dam- age to the pads and to the disk surface.

  • Page 118: Tires

    TIRES  WARNING  WARNING Failure to perform break-in of the tires could cause tire slip The tires on your motorcycle and loss of control, which form the crucial link between could result in an accident. your motorcycle and the road. Failure to take the precautions Use extra care when riding on below may result in an accident...
  • Page 119 Tire Pressure and Loading Tire Condition and Type Proper tire pressure and proper Tire condition and tire type affect tire loading are important factors. motorcycle performance. Cuts or Overloading your tires can lead to cracks in the tires can lead to tire tire failure and loss of vehicle con- failure and loss of motorcycle con- trol.
  • Page 120 Triangle mark • Ask your Suzuki dealer or a NOTE: The “Triangle mark” mark qualified mechanic to per- indicates the place where the form tire repair, replacement, wear bars are molded into the tire.

  • Page 121: Side Stand/Ignition Interlock System

    Suzuki dealer or a • Replace the tire if it is punc- qualified service mechanic. tured in the sidewall area, or if a puncture in the tread area is larger than 6 mm (3/16 in).

  • Page 122: Front Wheel Removal

    FRONT WHEEL REMOVAL  WARNING 1. Place the motorcycle on the side stand. If the side stand/ignition inter- lock system is not working properly, it is possible to ride the motorcycle with the side stand in the down position. This may interfere with rider control during a left turn and could cause an accident.
  • Page 123 5. Loosen the axle holder bolts 8. Draw out the axle shaft. 6. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end. 7. Carefully position a jack under the exhaust pipe and raise until the front wheel is slightly off the ground.
  • Page 124  WARNING Failure to extend brake pads after installing the wheel can cause poor braking perfor- mance and may result in an accident. Before riding, “pump” the 12.Hold the shaft and tighten the brake lever repeatedly until axle nut 5 to the specified brake pads are pressed against torque.

  • Page 125: Rear Wheel Removal

    Removing the rear wheel with- use one, ask your authorized out use of an accessory stand Suzuki dealer to check the can result in your motorcycle bolts and nuts. falling over and being dam- aged.
  • Page 126 3. Place an accessory service stand or an equivalent stand under the swingarm to lift the rear wheel slightly off the ground. NOTICE Improper jacking may cause damage to the oil filter. 6. With the wheel moved forward, remove the chain from the Do not place the jack under the sprocket.
  • Page 127 It is very difficult to force procedure, have your autho- the pads back into the caliper rized Suzuki dealer or a qual- assembly. ified mechanic do this. 9. To replace the wheel reverse...

  • Page 128: Light Bulb Replacement

    LIGHT BULB REPLACEMENT HEADLIGHT To replace the headlight bulbs, The wattage rating of each bulb is perform the following steps: shown in the following chart. When replacing a burned-out Low Beam Bulb bulb, always use the same watt- age rating according to the follow- ing chart.
  • Page 129 5. Pull off the bulb 7 from the socket 6. NOTICE The headlight bulb’s life may be shortened by oil from your fingers if you touch it. 2. Push the lock on the connector When replacing the headlight and pull off the connector 3. bulb, be careful not to touch 3.
  • Page 130 High Beam Bulb 1. Remove the fasteners. 3. Disconnect the coupler 2. Turn the bulb 3 counterclock- wise and remove it. 2. Remove the bolts. Unhook the hooks. Remove the under NOTICE cover 1. The headlight bulb’s life may be shortened by oil from your fingers if you touch it.
  • Page 131 Headlight Beam Adjustment POSITION LIGHT The headlight beam can be adjusted both up and down or right and left if necessary. 1. Pull out the socket. Low beam 2. Pull off the bulb from the socket. High beam To adjust the beam up and down: Turn the adjuster 1 clockwise or counterclockwise.
  • Page 132 FRONT TURN SIGNAL LIGHT To replace the front turn signal light bulb, follow these directions. 3. Push in the bulb and turn it counterclockwise. NOTICE 1. Remove the screw and take off the front turn signal assembly. Overtightening screws when reinstalling the lens may cause the lens to crack.
  • Page 133 REAR TURN SIGNAL LIGHT LICENSE PLATE LIGHT To replace the rear turn signal To replace the license plate light light bulb, follow these directions. bulb, follow the procedure steps: 1. Remove the nuts 1. 1. Remove the screw and take off the lens.

  • Page 134: Fuses

    4. To fit the replacement bulb, replacing the blown fuse with a push it in and twist it to the new fuse. Consult your Suzuki right while pushing. dealer for the electrical system check and repair.
  • Page 135 Fuse List • 30A MAIN fuse protects all electrical circuits. • 10A HEAD-HI fuse protects the headlight high beam and speedometer. • 10A HEAD-LO fuse protects the headlight low beam. • 10A IGNITION fuse protects the cooling fan relay, ignition coils, starter relay, fuel pump The fuses are located under the relay, solenoid, ECM, oxygen...

  • Page 136: Catalytic Converter

    CATALYTIC CONVERTER NOTICE The purpose of the catalytic con- verter is to minimize the amount Improper motorcycle opera- of harmful pollutants in your tion can cause catalyst or other motorcycle’s exhaust. Use of motorcycle damage. leaded fuel motorcycles equipped with catalytic converters To avoid damage to the catalyst is prohibited because lead deacti- or other related components,...

  • Page 138: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..................8-2 IGNITION SYSTEM CHECK ................8-3...
  • Page 139 Suzuki dealer. Refer to the “INSTRU- NOTICE MENT PANEL” section for an Improper repairs or adjust- explanation of the electronic con- trol indicator light.
  • Page 140 Replace it if neces- machine authorized sary. Retry the above proce- Suzuki dealer. Refer to the dure with the cleaned spark “INSTRUMENT PANEL” sec- plug or a new one. tion for an explanation of the 4.

  • Page 142: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................9-2 PROCEDURE FOR RETURNING TO SERVICE ..........9-3 CORROSION PREVENTION ................9-3 MOTORCYCLE CLEANING ................9-4 INSPECTION AFTER CLEANING ............... 9-7...

  • Page 143: Storage Procedure

    Suzuki recommends that you rags to prevent humidity from trust this maintenance work to entering. your Suzuki dealer. If you wish to service the machine for storage BATTERY yourself, follow the general guide- 1. Remove the battery from the...

  • Page 144: Procedure For Returning To Service

    PROCEDURE FOR CORROSION PREVENTION RETURNING TO SERVICE It is important to take good care of your motorcycle to protect it from 1. Clean the entire motorcycle. corrosion and keep it looking new 2. Remove the oily rags from the for years to come. air cleaner intake and muffler outlet.

  • Page 145: Motorcycle Cleaning

    Do not use gone through to the bare hard materials which metal, have a Suzuki dealer scratch the paint. make the repair. 2. Wash the entire motorcycle • Store your motorcycle in a dry, with a mild detergent or car well-ventilated area.
  • Page 146 NOTE: The headlight lens can be NOTICE fogged after washing the motorcy- cle or riding in the rain. Headlight High pressure washers such as fogging will be cleared gradually those found at coin-operated when the headlight is turned on. car washes have enough pres- When clearing the headlight lens sure to damage the parts of fogging, run the engine to avoid...
  • Page 147 PLASTIC PARTS WAXING THE MOTORCYCLE Plastic parts such as headlight After washing the motorcycle, lens, speedometer display, wind- waxing and polishing are recom- shield and fairing, are easy to be mended to further protect and damaged. When such part is beautify the paint.

  • Page 148: Inspection After Cleaning

    INSPECTION AFTER CLEANING For extended life of your motorcy- cle, lubricate it according to the “LUBRICATION POINTS” section.  WARNING Operating the motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes.
  • Page 150 CONSUMER INFORMATION WARRANTIES ....................10-2 EMISSION CONTROL SYSTEMS ..............10-3 REPORTING SAFETY DEFECTS ..............10-4 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-5 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....10-6 SERIAL NUMBER LOCATION ................10-7 LOCATION OF LABELS ................... 10-8 10-1...

  • Page 151: Consumer Information

    Suzuki limited warranties and the CONSUMER Federal and California Emission INFORMATION Control System Limited Warranty may not cover damage caused by WARRANTIES modifications that would change The warranties for your motorcy- the original vehicle specifications cle are explained in a separate...

  • Page 152: Emission Control Systems

    If parts tions set specific standards for replacement is necessary, replace exhaust emission output levels the parts with Genuine Suzuki and fuel permeation emissions, parts or their equivalent. Installing as well as particular servicing improper replacement parts or requirements.

  • Page 153: Reporting Safety Defects

    REPORTING SAFETY DEFECTS To contact Suzuki Motor of Amer- ica, Inc., owners in the continental If you believe that your vehicle United States can call toll-free 1- has a defect which could cause a 800-444-5077, or write to: Suzuki crash or could cause injury or Motor of America, Inc.

  • Page 154: Tampering With Noise Control System Prohibited

    Whenever replacing parts on your 2. The use of the vehicle after motorcycle, Suzuki recommends such device or element of that you use genuine Suzuki design has been removed or replacement parts or their equiva- rendered inoperative by any lent.

  • Page 155: On-Board Motorcycle Computer Data Information

    Suzuki may use as engine speed and throttle the data for research conducted position are monitored to pro- by Suzuki, make the data avail- vide emission control and to able for outside research if need provide optimum fuel econ- is shown and confidentiality is omy.

  • Page 156: Serial Number Location

    SERIAL NUMBER LOCATION Write down the serial numbers here for your future reference. You need to know the frame and engine serial numbers to get title Frame No.: documents for your motorcycle. You also need these numbers to help your dealer when you order Engine No.: parts.

  • Page 157: Location Of Labels

    If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. DUAL RIDING SOLO RIDING COLD TIRE...
  • Page 158 V E H I C L E E M I S S I O N C O N T R O L I N F O R M A T I O N S U Z U K I M O T O R C O R P O R A T I O N D I S P L A C E M E N T : E N G I N E F A M I L Y : P E R M E A T I O N F A M I L Y :...

  • Page 159: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2030 mm (79.9 in) Overall width............ 710 mm (28.0 in) Overall height ..........1135 mm (44.7 in) Wheelbase ............1385 mm (54.5 in) Ground clearance..........130 mm (5.1 in) Seat height ............810 mm (31.9 in) Curb mass ............
  • Page 160 ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK CR9EIA-9 or DENSO IU27D Battery .............12V 28.8 kC(8 Ah)/10 HR Generator ............Three-phase A.C. generator Main fuse............30A Fuse ..............10/10/10/10/10/15A Headlight ............12V 55W (H7) + 12V 65W (H9) Turn signal light ..........12V 21W × 4 Brake light/Taillight ..........LED Position light ............12V 5W ×...
  • Page 161 INDEX ACCESSORIES AND EMISSION CONTROL LOADING ....... 1-5 SYSTEMS ......10-3 ACCESSORY INSTALLATION ENGINE COOLANT .....7-28 GUIDELINES......6-2 ENGINE COOLANT ACCESSORY USE ....6-2 SOLUTION ......2-6 AIR CLEANER ..... 7-10 ENGINE IDLE SPEED INSPECTION......7-26 ENGINE OIL ....2-4 7-20 BATTERY....... 7-8 BE EXTRA SAFETY- CONSCIOUS ON BAD FOOTRESTS AND...
  • Page 162 IF A COLLISION IS IMMINENT, MAINTENANCE DO SOMETHING ....1-3 SCHEDULE ......7-2 IF YOU DON’T HAVE A HELMET, MODIFICATION .....6-4 BUY A HELMET AND WEAR IT MOST ACCIDENTS CAN BE EVERY TIME YOU RIDE ..1-2 AVOIDED .......1-2 IGNITION SWITCH ....3-5 MOTORCYCLE IGNITION SYSTEM CLEANING ......9-4...
  • Page 163 REAR BRAKE PEDAL ..3-30 TAMPERING WITH NOISE REAR WHEEL CONTROL SYSTEM REMOVAL......7-46 PROHIBITED......10-5 REPORTING SAFETY THROTTLE CABLE PLAY..7-26 DEFECTS......10-4 TIRES ........7-39 RIDING ON HILLS ....5-6 TOOLS ........7-6 RIGHT HANDLEBAR ... 3-25 USING THE SEAT LOCK AND HELMET TRANSMISSION ....5-5 HOLDERS ......

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