User Manuals: Suzuki GSX-R600 2007 Sport Motorcycle

Manuals and User Guides for Suzuki GSX-R600 2007 Sport Motorcycle. We have 1 Suzuki GSX-R600 2007 Sport Motorcycle manual available for free PDF download: Service Manual

Suzuki GSX-R600 2007 Service Manual

Suzuki GSX-R600 2007 Service Manual (522 pages)

Brand: Suzuki | Category: Motorcycle | Size: 52 MB

Table of Contents

General Information 1

8
- Fi System Diagnosis
  2
- Electrical System
  2
- General Information
  2
- Periodic Maintenance
  2
- Servicing Information
  2
- Warning/Caution/Note
  9
- General Precautions
  9
- Suzuki Gsx-R750K6 ('06-Model)
  11
- Serial Number Location
  11
- Fuel, Oil and Engine Coolant Recommendation
  12
  - Fuel (for Usa and Canada)
    12
  - Fuel (for Other Countries)
    12
  - Engine Oil (for Usa)
    12
  - Engine Oil (for Other Countries)
    12
  - Brake Fluid
    12
  - Front Fork Oil
    13
  - Engine Coolant
    13
  - Water for Mixing
    13
  - Anti-Freeze/Engine Coolant
    13
  - Liquid Amount of Water/Engine Coolant
    13
- Break-In Procedures
  14
- Cylinder Identification
  14
- Information Labels
  15
- Specifications
  16
  - Dimensions and Dry Mass
    16
  - Engine
    16
  - Drive Train
    16
  - Chassis
    17
  - Electrical
    17
  - Capacities
    17
Periodic Maintenance

18
- Periodic Maintenance Schedule
  19
  - Periodic Maintenance Chart
    19
  - Lubrication Points
    20
- Maintenance and Tune-Up Procedures
  21
  - Air Cleaner
    21
  - Spark Plug
    22
  - Valve Clearance
    24
  - Engine Oil and Oil Filter
    29
  - Exhaust Control Valve
    30
  - Fuel Line
    31
  - Engine Idle Speed
    31
  - Throttle Valve Synchronization
    32
  - Evaporative Emission Control System (E-33 Only)
    32
  - Pair (Air Supply) System
    32
  - Throttle Cable Play
    32
  - Clutch
    33
  - Cooling System
    34
    
    ENGINE COOLANT Change
    34
    
    Engine Coolant Level Check
    34
  - Drive Chain
    37
  - Brake
    40
  - Tires
    44
  - Steering
    44
  - Tire Tread Depth
    44
  - Front Fork
    45
  - Rear Suspension
    45
  - Exhaust Pipe Bolt and Nut
    46
  - Chassis Bolts and Nuts
    47
- Compression Pressure Check
  49
  - Compression Test Procedure
    49
- Oil Pressure Check
  50
- Sds Check
  51
  - Data at the Time of Racing
    52
Engine

54
- Engine Components Removable with Engine in Place
  55
- Engine Removal and Installation
  56
  - Engine Removal
    56
  - Engine Installation
    63
- Engine Disassembly
  67
- Engine Components Inspection and Service
  80
  - Cylinder Head Cover
    80
  - Cmp Sensor
    80
  - Pair Reed Valve
    80
  - Crankcase Breather Reed Valve
    81
  - Pcv Hose
    81
  - Camshaft
    82
  - Camshaft Runout
    83
  - Cam Chain Tension Adjuster
    84
  - Cam Chain Tensioner
    84
  - Cam Chain Guide
    85
  - Cylinder Head and Valve
    85
  - Clutch
    92
  - Clutch Lifter
    93
  - Oil Pump
    95
  - Starter Clutch
    95
  - Generator
    97
  - Water Pump
    97
  - Gearshift System
    97
  - Oil Pressure Regulator
    98
  - Oil Strainer
    98
  - Transmission
    99
  - Cylinder
    102
  - Piston and Piston Ring
    103
    
    Piston Ring Groove Width
    104
    
    Piston Ring Thickness
    104
    
    Piston Ring End Gap
    104
  - Crankcase
    105
  - Balancer Shaft
    115
  - Balancer Shaft Journal Bearing
    115
  - Crankshaft and Conrod
    118
  - Crankshaft Journal Bearing
    122
  - Crankshaft Thrust Bearing
    125
- Engine Reassembly
  127
Fi System Diagnosis

157
Fuel System and Throttle Body

264
- Fuel Delivery System
  265
- Fuel System
  266
  - Fuel Tank Lift-Up
    266
  - Fuel Tank Removal
    267
  - Fuel Tank Installation
    267
  - Fuel Pressure Inspection
    267
  - Fuel Pump Inspection
    268
  - Fuel Discharge Amount Inspection
    269
  - Fuel Pump Relay Inspection
    270
  - Fuel Pump and Fuel Filter Removal
    271
  - Fuel Mesh Filter Inspection and Cleaning
    273
  - Fuel Pump and Fuel Mesh Filter Installation
    273
- Throttle Body
  276
  - Construction
    276
  - Air Cleaner Box Removal and Installation
    277
  - Throttle Body Removal
    278
  - Throttle Body Disassembly
    279
  - Throttle Body Cleaning
    281
  - Inspection
    281
  - Throttle Body Reassembly
    282
  - Throttle Body Installation
    284
  - Stp Sensor Adjustment
    285
  - Fuel Injector Removal
    286
  - Fuel Injector Inspection
    286
  - Fuel Injector Installation
    286
  - Fast Idle
    287
  - Fast Idle Adjustment
    287
  - Throttle Valve Synchronization
    289
  - Throttle Position Sensor (Tps) Setting
    290
Exhaust System

291
- Exhaust System
  292
  - Exhaust Control System
    292
  - Operation
    293
- Excva (Exhaust Control Valve Actuator) and Excv (Exhaust Control Valve)
  294
  - Excva Removal
    294
  - Excva Pulley Inspection
    295
  - Excva Installation
    295
  - Excva Inspection
    296
  - Excv Cable Replacement
    297
  - Excva Adjustment
    298
  - Excv/Exhaust Pipe, Muffler Removal
    300
  - Excv Inspection
    302
  - Excv/Exhaust Pipe, Muffler Installation
    302
Cooling and Lubrication System

305
- Engine Coolant
  306
- Cooling Circuit
  307
  - Cooling Circuit Inspection
    307
- Radiator and Water Hoses
  308
  - Radiator Removal
    308
  - Radiator Cap Inspection
    308
  - Radiator Inspection and Cleaning
    308
  - Radiator Installation
    309
  - Water Hose Inspection
    309
- Cooling Fan
  310
  - Removal
    310
  - Inspection
    310
  - Installation
    310
  - Cooling Fan Relay Inspection
    311
- Ect Sensor
  311
  - Removal
    311
  - Inspection
    311
  - Installation
    312
- Thermostat
  313
  - Removal
    313
  - Inspection
    313
  - Installation
    314
- Water Pump
  315
  - Removal and Disassembly
    315
  - Inspection
    317
  - Reassembly and Installation
    318
- Lubrication System
  321
  - Oil Cooler
    321
  - Oil Pressure
    322
  - Oil Filter
    322
  - Oil Pressure Regulator
    322
  - Oil Strainer
    322
  - Oil Jet
    322
  - Oil Pump
    322
  - Oil Pressure Switch
    323
  - Engine Lubrication System Chart
    323
  - Engine Lubrication System
    324
Chassis

326
- Exterior Parts
  328
  - Fastener Removal and Installation
    328
  - Body Cowling Cover and Lower Bracket Cover
    330
  - Inner under Cowling
    330
  - Under Cowling
    330
  - Screen
    331
  - Body Cowling
    331
  - Air Intake Pipe
    332
  - Cowling Brace
    332
  - Front Seat
    332
  - Fuel Tank Lower Side Cover
    332
  - Rear Seat/Seat Tail Cover
    333
  - Frame Cover
    333
- Front Wheel
  334
  - Construction
    334
  - Removal and Disassembly
    335
  - Inspection
    337
  - Reassembly and Installation
    338
- Front Fork
  342
  - Construction
    342
  - Removal and Disassembly
    343
  - Inspection
    346
  - Reassembly
    347
  - Installation
    351
  - Suspension Setting
    352
- Steering Damper
  353
  - Construction
    353
  - Removal
    354
  - Inspection
    354
  - Installation
    354
- Steering
  355
  - Construction
    355
  - Removal
    356
  - Inspection and Disassembly
    357
  - Reassembly
    358
  - Installation
    358
  - Steering Tension Adjustment
    360
- Handlebars
  361
  - Construction
    361
  - Removal
    361
  - Installation
    362
- Rear Wheel
  365
  - Construction
    365
  - Removal
    366
  - Inspection and Disassembly
    367
  - Reassembly and Installation
    369
- Rear Shock Absorber
  373
  - Construction
    373
  - Removal
    374
  - Inspection
    376
  - Rear Shock Absorber Scrapping Procedure
    376
  - Installation
    377
  - Suspension Setting
    378
- Rear Suspension
  379
  - Construction
    379
  - Removal
    380
  - Inspection
    381
  - Disassembly
    384
  - Reassembly and Installation
    385
  - Final Inspection and Adjustment
    388
- Front Brake
  389
  - Construction
    389
  - Brake Pad Replacement
    390
  - Brake Fluid Replacement
    391
  - Caliper Removal
    392
  - Caliper Disassembly
    392
  - Caliper Inspection
    393
  - Caliper Reassembly
    393
  - Caliper Installation
    394
  - Brake Disc Inspection
    395
  - Master Cylinder Removal and Disassembly
    396
  - Master Cylinder Inspection
    397
  - Master Cylinder Reassembly
    398
  - Master Cylinder Installation
    399
- Rear Brake
  400
  - Construction
    400
  - Brake Pad Replacement
    401
  - Brake Fluid Replacement
    402
  - Caliper Removal and Disassembly
    402
  - Caliper Inspection
    404
  - Service Limit
    404
  - Caliper Reassembly
    405
  - Caliper Installation
    406
  - Master Cylinder Removal and Disassembly
    406
  - Master Cylinder Inspection
    408
  - Master Cylinder Reassembly
    408
  - Master Cylinder Installation
    409
- Tire and Wheel
  410
  - Tire Removal
    410
  - Inspection
    410
  - Valve Inspection
    411
  - Tire Installation
    412
  - Balancer Weight Installation
    413
- Drive Chain
  414
  - Drive Chain Cutting
    414
  - Drive Chain Connecting
    415
Electrical System

418
- Cautions in Servicing
  420
  - Connector
    420
  - Coupler
    420
  - Clamp
    420
  - Fuse
    420
  - Semi-Conductor Equipped Part
    421
  - Battery
    421
  - Connecting the Battery
    421
  - Wiring Procedure
    421
  - Using the Multi-Circuit Tester
    422
- Location of Electrical Components
  423
- Charging System
  425
  - Troubleshooting
    425
  - Inspection
    426
- Starter System and Side-Stand/Ignition Interlock System
  429
  - Troubleshooting
    429
  - Starter Motor Removal
    430
  - Starter Motor Disassembly
    431
  - Starter Motor Inspection
    431
  - Starter Motor Reassembly
    432
  - Starter Relay Inspection
    433
  - Side Stand/Ignition Interlock System Parts Inspection
    434
- Ignition System
  437
  - IMMOBILIZER (Except for E-03, 28, 33)
    438
  - Troubleshooting
    440
  - Inspection
    442
- Combination Meter
  446
  - Description
    446
  - Removal and Disassembly
    447
  - Inspection
    448
- Lamps
  452
  - Headlight, Brake Light/Taillight, License Plate Light and Turn Signal Light
    452
- Relays
  454
  - Turn Signal/Side-Stand Relay
    454
  - Starter Relay
    454
  - Fuel Pump Relay
    454
  - Cooling Fan Relay
    454
  - Ignition Switch Removal
    455
  - Ignition Switch Installation
    455
  - Switches Inspection
    456
- Battery
  457
  - Specifications
    457
  - Initial Charging
    457
  - Servicing
    459
  - Recharging Operation
    459
Servicing Information

460
- Troubleshooting
  461
  - Fi System Malfunction Code and Defective Condition
    461
  - Engine
    465
  - Radiator (Cooling System)
    471
  - Chassis
    472
  - Brakes
    473
  - Electrical
    474
  - Battery
    475
- Wiring Harness, Cable and Hose Routing
  476
  - Wiring Harness Routing
    476
  - HO2 SENSOR HARNESS ROUTING (for E-02, 19)
    479
  - Cable Routing
    480
  - Fuel Tank Hose Routing
    481
  - Cooling System Hose Routing
    482
  - Front Brake Hose Routing
    483
  - Rear Brake Hose Routing
    484
  - Fuel Tank Installation
    485
  - Cowling Installation
    485
  - Frame Cover Installation
    486
  - Seat Lock Cable Routing
    487
  - Rear Fender Installation
    487
  - Side-Stand Installation
    489
  - Under Cowling Cushion Rubber/Heat Shield Installation
    489
  - Front Footrest Installation
    490
  - Rear View Mirror Installation
    491
  - Special Tools
    492
- Tightening Torque
  496
  - Engine
    496
  - Fi System and Intake Air System
    497
  - Chassis
    498
  - Tightening Torque Chart
    499
- Service Data
  500
  - Emission Control Systems
    511
    
    Fuel Injection System
    511
    
    Crankcase Emission Control System
    512
    
    Exhaust Emission Control System (Pair System)
    513
    
    Noise Emission Control System
    514
  - Pair (Air Supply) System and Emission Control System Inspection
    515
    
    Pair Hoses
    515
    
    Pair Reed Valve
    515
    
    Pcv Hose
    515
    
    Pair Control Solenoid Valve
    516
  - Pair (Air Supply) System Hose Routing
    517
  - HO2 SENSOR INSPECTION (for E-02, 19)
    518

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