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GSX-R600
Service manual
Suzuki GSX-R600 Service Manual
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Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Foreword
Group Index
How to Use this Manual
Component Parts and Work to be Done
Symbol
Abbreviations Used in this Manual
Wire Color
General Information
Contents
Warning/Caution/Note
Suzuki GSX-R600K4 ('04-Model) View
Serial Number Location
Fuel, Oil and Engine Coolant Recommendation Fuel (for USA and Canada)
Fuel (for Other Countries)
Engine Oil (for USA)
Engine Oil (for Other Countries)
Engine Coolant
Water for Mixing
Anti-Freeze/Engine Coolant
Liquid Amount of Water/Engine Coolant
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Dimensions and Dry Mass
Drive Train
Electrical
Capacities
Periodic Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Air Cleaner
Spark Plug and Ignition Coil/Plug Cap Removal
Heat Range
Carbon Deposits
Spark Plug Gap
Electrode's Condition
Spark Plug and Ignition Coil/Plug Cap Installation
Valve Clearance
Valve Clearance Adjustment
Intake Side
Tappet Shim Selection Table
Exhaust Side
Engine Oil and Oil Filter
Engine Oil Replacement
Oil Filter Replacement
Fuel Line
Engine Idle Speed
Throttle Valve Synchronization
Evaporative Emission Control System (E-33 Only)
Pair (Air Supply) System
Throttle Cable Play
Clutch
Cooling System
Engine Coolant Level Check
Engine Coolant Change
Air Bleeding the Cooling Circuit
Radiator Hoses
Drive Chain
Checking
Adjusting
Cleaning and Lubricating
Brake Fluid Level Check
Brake Pads
Front Brake
Rear Brake
Brake Pedal Height
Brake Light Switch
Air Bleeding from Brake Fluid Circuit
Front Brake (Caliper Side)
Front Brake (Master Cylinder Side)
Tire Tread Condition
Tire Pressure
Steering
Front Fork
Rear Suspension
Exhaust Pipe Bolt and Muffler Bolt and Nut
Chassis Bolts and Nuts
Compression Pressure Check
Compression Pressure Specification
Compression Test Procedure
Oil Pressure Check
Oil Pressure Specification
Oil Pressure Test Procedure
Engine
Engine Components Removable with Engine in Place
Engine Center
Engine Right Side
Engine Left Side
Engine Removal
Radiator
Exhaust Pipe and Muffler
Electric Parts and Pair Hose
Engine Sprocket and Gear Shift Lever
Engine Mounting
Engine Installation
Engine Disassembly
Starter Motor
Cylinder Head Cover and Pair Reed Valve
Camshafts
Cylinder Head
Oil Pump
Gearshift System
Starter Idle Gear
Starter Clutch
Cam Chain, Cam Chain Tensioner and Cam Chain Guide
CKP Sensor
Generator Cover
Generator Rotor
Water Pump
Gear Position Switch
Crankcase Breather (PCV) Cover
Oil Filter
Lower Crank Case
Middle Crankcase
Crankshaft
Piston and Conrod
Engine Components Inspection and Service
Cylinder Head Cover
CMP Sensor
Pair Reed Valve
PCV Hose
Camshaft Identification
Cam Wear
Camshaft Journal Wear
Сamshaft Runout
Сam Sprocket
Сam Chain Tension Adjuster
Сam Chain Tensioner
Сam Chain Guide
Сylinder Head and Valve
Valve and Valve Spring Disassembly
Cylinder Head Distortion
Valve Stem Runout
Valve Head Radial Runout
Valve Stem and Valve Face Wear Condition
Valve Stem Deflection
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width Inspection
Valve Seat Servicing
Initial Seat Cut
Top Narrowing Cut
Bottom Narrowing Cut
Final Seat Cut
Valve Spring
Valve and Valve Spring Reassembly
Intake Pipe
Water Bypass Union
Clutch Drive Plates Inspection
Clutch Spring Inspection
Clutch Bearing Inspection
Clutch Sleeve Hub/Primary Driven Gear Assembly
Generator
Gearshift Shaft/Gearshift Arm Disassembly
Gearshift Shaft/Gearshift Arm Inspection
Gearshift Shaft/Gearshift Arm Reassembly
Oil Pressure Regulator
Transmission
Disassembly
Reassembly
Transmission Parts Location
Cylinder Distortion
Cylinder Bore
Piston and Piston Ring
Piston Diameter
Piston-To-Cylinder Clearance
Piston Pin and Pin Bore
Piston Ring-To-Groove Clearance
Piston Ring Free End Gap and Piston Ring End Gap
Crankcase
Gearshift Fork and Gearshift Cam
Gearshift Fork-To-Groove Clearance
Gearshift Fork Groove Width
Gearshift Fork Thickness
Gearshift Cam Bearing and Gearshift Shaft Bearing
Bearing Inspection
Bearing Removal
Installation
Oil Jet
Inspection and Cleaning
Plug
Conrod Big End Side Clearance
Conrod-Big End Bearing Inspection
Conrod-Big End Bearing Selection
Crankshaft and Conrod
Crankshaft Runout
Conrod Small End I.D.
Crank Pin O.D.
Bearing Thickness
Bearing Selection Table
Conrod I.D.
Crankshaft Journal Bearing
Selection
Crankcase I.D. Specification
Crankshaft Journal O.D. Specification
Bearing Thickness Specification
Crankshaft Thrust Bearing
Crankshaft Thrust Clearance Adjustment
Thrust Bearing Selection Table
Engine Reassembly
Piston Ring
Oil Strainer
Oil Pan
Oil Pressure Switch
Crankcase Breather Cover
Cam Chain Drive Sprocket
Cam Chain Tensioner and Cam Chain Guide
Clutch Cover
Camshaft
Cam Chain Tension Adjuster
FI System Diagnosis
Precautions in Servicing
Electrical Parts
Connector/Coupler
Fuse
Ecm/Various Sensors
Electrical Circuit Inspection Procedure
Open Circuit Check
Continuity Check
Voltage Check
Short Circuit Check (Wire Harness to Ground)
Using the Multi-Circuit Tester
Using the Tester
FI System Technical Features
Injection Time (Injection Volume)
Compensation of Injection Time (Volume)
Injection Stop Control
Injection Timing
FI System Parts Location
FI System Wiring Diagram
Self-Diagnosis Function
User Mode
Dealer Mode
TPS Adjustment
Fail-Safe Function
FI System Troubleshooting
Self-Diagnostic Procedures
Self-Diagnosis Reset Procedure
Malfunction Code and Defective Condition
"C11" CMP Sensor Circuit Malfunction
"C12" CKP Sensor Circuit Malfunction
"C13" IAP Sensor Circuit Malfunction
"C14" TP Sensor Circuit Malfunction
"C15" ECT Sensor Circuit Malfunction
Output Voltage
"C21" IAT Sensor Circuit Malfunction
"C22" AP Sensor Circuit Malfunction
"C23" to Sensor Circuit Malfunction
"C28" STV Actuator Circuit Malfunction
"C29" STP Sensor Circuit Malfunction
"C31" GP Switch Circuit Malfunction
"C32", "C33", "C34" or "C35" Fuel Injector Circuit Malfunction
"C41" FP Relay Circuit Malfunction
"C42" IG Switch Circuit Malfunction
"C49" Pair Control Solenoid Valve Circuit Malfunction
Sensors
Fuel System and Throttle Body
Fuel Delivery System
Fuel System
Fuel Tank Lift-Up
Fuel Tank Removal
Fuel Pressure Inspection
Fuel Pump Inspection
Fuel Discharge Amount Inspection
Fuel Pump Relay Inspection
Fuel Pump and Fuel Filter Removal
Construction
Fuel Mesh Filter Inspection and Cleaning
Fuel Pump and Fuel Mesh Filter Installation
Throttle Body Construction
Air Cleaner Box Removal
Throttle Body Removal
Throttle Body Disassembly
Throttle Body Cleaning
Throttle Body Reassembly
Throttle Body Installation
Air Cleaner Box Installation
STP Sensor Adjustment
Fuel Injector Removal
Fuel Injector Inspection
Fuel Injector Installation
Fast Idle Adjustment
Use for Digital Vacuum Tester
Use for Vacuum Balancer Gauge
Calibrating each Vacuum Gauge
Throttle Position Sensor (TPS) Setting
Exhaust System
Precautions for Exhaust System
Exhaust System Components
Cooling and Lubrication System
Cooling Circuit Inspection
Radiator and Water Hoses
Radiator Removal
Radiator Cap Inspection
Radiator Inspection and Cleaning
Water Hose Inspection
Cooling Fan
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Troubleshooting
FI System Troubleshooting
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Troubleshooting
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