Suzuki GSX-R600 2007 Manuals

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

Suzuki GSX-R600 2007 Service Manual

Suzuki GSX-R600 2007 Service Manual (523 pages)

Brand: Suzuki | Category: Motorcycle | Size: 52.87 MB
Table of contents
General Information2................................................................................................................................................................
Periodic Maintenance2................................................................................................................................................................
Fi System Diagnosis2................................................................................................................................................................
Electrical System2................................................................................................................................................................
Servicing Information2................................................................................................................................................................
Wiring Diagram2................................................................................................................................................................
How To Use This Manual3................................................................................................................................................................
Abbreviations Used In This Manual5................................................................................................................................................................
Table Of Contents8................................................................................................................................................................
General Precautions9................................................................................................................................................................
Serial Number Location11................................................................................................................................................................
Suzuki Gsx-r750k6 ('06-model)11................................................................................................................................................................
Brake Fluid12................................................................................................................................................................
Fuel, Oil And Engine Coolant Recommendation12................................................................................................................................................................
Fuel (for Usa And Canada)12................................................................................................................................................................
Fuel (for Other Countries)12................................................................................................................................................................
Engine Oil (for Usa)12................................................................................................................................................................
Engine Oil (for Other Countries)12................................................................................................................................................................
Front Fork Oil13................................................................................................................................................................
Break-in Procedures14................................................................................................................................................................
Cylinder Identification14................................................................................................................................................................
Information Labels15................................................................................................................................................................
Dimensions And Dry Mass16................................................................................................................................................................
Drive Train16................................................................................................................................................................
Periodic Maintenance Schedule19................................................................................................................................................................
Periodic Maintenance Chart19................................................................................................................................................................
Lubrication Points20................................................................................................................................................................
Air Cleaner21................................................................................................................................................................
Maintenance And Tune-up Procedures21................................................................................................................................................................
Spark Plug22................................................................................................................................................................
Valve Clearance24................................................................................................................................................................
Engine Oil And Oil Filter29................................................................................................................................................................
Fuel Line31................................................................................................................................................................
Engine Idle Speed31................................................................................................................................................................
Throttle Valve Synchronization32................................................................................................................................................................
Throttle Cable Play32................................................................................................................................................................
Cooling System34................................................................................................................................................................
Drive Chain37................................................................................................................................................................
Tire Tread Depth44................................................................................................................................................................
Front Fork45................................................................................................................................................................
Rear Suspension45................................................................................................................................................................
Exhaust Pipe Bolt And Nut46................................................................................................................................................................
Chassis Bolts And Nuts47................................................................................................................................................................
Compression Pressure Check49................................................................................................................................................................
Compression Test Procedure49................................................................................................................................................................
Oil Pressure Check50................................................................................................................................................................
Sds Check51................................................................................................................................................................
Data At The Time Of Racing52................................................................................................................................................................
Engine Components Removable With Engine In Place55................................................................................................................................................................
Engine Removal And Installation56................................................................................................................................................................
Engine Removal56................................................................................................................................................................
Engine Installation63................................................................................................................................................................
Engine Disassembly67................................................................................................................................................................
Cylinder Head Cover80................................................................................................................................................................
Engine Components Inspection And Service80................................................................................................................................................................
Cmp Sensor80................................................................................................................................................................
Crankcase Breather Reed Valve81................................................................................................................................................................
Camshaft Runout83................................................................................................................................................................
Cam Chain Tension Adjuster84................................................................................................................................................................
Cam Chain Tensioner84................................................................................................................................................................
Cam Chain Guide85................................................................................................................................................................
Cylinder Head And Valve85................................................................................................................................................................
Clutch Lifter93................................................................................................................................................................
Oil Pump95................................................................................................................................................................
Starter Clutch95................................................................................................................................................................
Water Pump97................................................................................................................................................................
Gearshift System97................................................................................................................................................................
Oil Pressure Regulator98................................................................................................................................................................
Oil Strainer98................................................................................................................................................................
Piston And Piston Ring103................................................................................................................................................................
Piston Ring Groove Width104................................................................................................................................................................
Piston Ring Thickness104................................................................................................................................................................
Piston Ring End Gap104................................................................................................................................................................
Balancer Shaft115................................................................................................................................................................
Balancer Shaft Journal Bearing115................................................................................................................................................................
Crankshaft And Conrod118................................................................................................................................................................
Crankshaft Journal Bearing122................................................................................................................................................................
Crankshaft Thrust Bearing125................................................................................................................................................................
Engine Reassembly127................................................................................................................................................................
Precautions In Servicing159................................................................................................................................................................
Electrical Parts159................................................................................................................................................................
Ecm/various Sensors160................................................................................................................................................................
Electrical Circuit Inspection Procedure162................................................................................................................................................................
Fi System Technical Features166................................................................................................................................................................
Injection Time (injection Volume)166................................................................................................................................................................
Compensation Of Injection Time (volume)167................................................................................................................................................................
Injection Stop Control167................................................................................................................................................................
Fi System Parts Location168................................................................................................................................................................
Fi System Wiring Diagram170................................................................................................................................................................
Ecm Terminal171................................................................................................................................................................
Self-diagnosis Function173................................................................................................................................................................
User Mode173................................................................................................................................................................
Dealer Mode174................................................................................................................................................................
Tps Adjustment176................................................................................................................................................................
Fail-safe Function177................................................................................................................................................................
Fi System Troubleshooting179................................................................................................................................................................
Customer Complaint Analysis179................................................................................................................................................................
Visual Inspection180................................................................................................................................................................
Self-diagnostic Procedures181................................................................................................................................................................
Self-diagnosis Reset Procedure181................................................................................................................................................................
Use Of Sds Diagnostic Procedures182................................................................................................................................................................
Show Data When Trouble184................................................................................................................................................................
Displaing Data At The Time Of Dtc184................................................................................................................................................................
Malfunction Code And Defective Condition185................................................................................................................................................................
C11" (p0340) Cmp Sensor Circuit Malfunction189................................................................................................................................................................
C12" (p0335) Ckp Sensor Circuit Malfunction191................................................................................................................................................................
C13" (p0105-h/l) Iap Sensor Circuit Malfunction194................................................................................................................................................................
C14" (p0120-h/l) Tp Sensor Circuit Malfunction200................................................................................................................................................................
C15" (p0115-h/l) Ect Sensor Circuit Malfunction205................................................................................................................................................................
C21" (p0110-h/l) Iat Sensor Circuit Malfunction209................................................................................................................................................................
C22" (p1450-h/l) Ap Sensor Circuit Malfunction213................................................................................................................................................................
C23" (p1651-h/l) To Sensor Circuit Malfunction219................................................................................................................................................................
C28" (p1655) Stv Actuator Circuit Malfunction223................................................................................................................................................................
C29" (p1654-h/l) Stp Sensor Circuit Malfunction226................................................................................................................................................................
C31" (p0705) Gp Switch Circuit Malfunction231................................................................................................................................................................
C41" (p0230-h/l) Fp Relay Circuit Malfunction239................................................................................................................................................................
C42" (p01650) Ig Switch Circuit Malfunction242................................................................................................................................................................
C60" (p0480) Cooling Fan Relay Circuit Malfunction259................................................................................................................................................................
Cmp Sensor Inspection261................................................................................................................................................................
Cmp Sensor Removal And Installation261................................................................................................................................................................
Ckp Sensor Inspection261................................................................................................................................................................
Ckp Sensor Removal And Installation261................................................................................................................................................................
Iap Sensor Inspection261................................................................................................................................................................
Iap Sensor Removal And Installation261................................................................................................................................................................
Tp Sensor Inspection261................................................................................................................................................................
Tp Sensor Removal And Installation261................................................................................................................................................................
Ect Sensor Inspection262................................................................................................................................................................
Ect Sensor Removal And Installation262................................................................................................................................................................
Iat Sensor Inspection262................................................................................................................................................................
Iat Sensor Removal And Installation262................................................................................................................................................................
Ap Sensor Inspection262................................................................................................................................................................
Ap Sensor Removal And Installation262................................................................................................................................................................
Stp Sensor Adjustment263................................................................................................................................................................
Fuel Delivery System265................................................................................................................................................................
Fuel System266................................................................................................................................................................
Fuel Tank Lift-up266................................................................................................................................................................
Fuel Tank Removal267................................................................................................................................................................
Fuel Pump Inspection268................................................................................................................................................................
Fuel Discharge Amount Inspection269................................................................................................................................................................
Fuel Pump Relay Inspection270................................................................................................................................................................
Fuel Pump And Fuel Filter Removal271................................................................................................................................................................
Fuel Mesh Filter Inspection And Cleaning273................................................................................................................................................................
Fuel Pump And Fuel Mesh Filter Installation273................................................................................................................................................................
Throttle Body276................................................................................................................................................................
Throttle Body Removal278................................................................................................................................................................
Throttle Body Disassembly279................................................................................................................................................................
Throttle Body Cleaning281................................................................................................................................................................
Throttle Body Reassembly282................................................................................................................................................................
Throttle Body Installation284................................................................................................................................................................
Fuel Injector Removal286................................................................................................................................................................
Fuel Injector Inspection286................................................................................................................................................................
Fuel Injector Installation286................................................................................................................................................................
Fast Idle287................................................................................................................................................................
Fast Idle Adjustment287................................................................................................................................................................
Throttle Position Sensor (tps) Setting290................................................................................................................................................................
Exhaust Control System292................................................................................................................................................................
Excva Removal294................................................................................................................................................................
Excva Pulley Inspection295................................................................................................................................................................
Excva Installation295................................................................................................................................................................
Excva Inspection296................................................................................................................................................................
Excv Cable Replacement297................................................................................................................................................................
Excva Adjustment298................................................................................................................................................................
Excv/exhaust Pipe, Muffler Removal300................................................................................................................................................................
Excv Inspection302................................................................................................................................................................
Excv/exhaust Pipe, Muffler Installation302................................................................................................................................................................
Engine Coolant306................................................................................................................................................................
Cooling Circuit307................................................................................................................................................................
Cooling Circuit Inspection307................................................................................................................................................................
Radiator And Water Hoses308................................................................................................................................................................
Radiator Removal308................................................................................................................................................................
Radiator Cap Inspection308................................................................................................................................................................
Radiator Inspection And Cleaning308................................................................................................................................................................
Radiator Installation309................................................................................................................................................................
Water Hose Inspection309................................................................................................................................................................
Cooling Fan310................................................................................................................................................................
Cooling Fan Relay Inspection311................................................................................................................................................................
Ect Sensor311................................................................................................................................................................
Removal And Disassembly315................................................................................................................................................................
Reassembly And Installation318................................................................................................................................................................
Lubrication System321................................................................................................................................................................
Oil Cooler321................................................................................................................................................................
Engine Lubrication System Chart323................................................................................................................................................................
Engine Lubrication System324................................................................................................................................................................
Exterior Parts328................................................................................................................................................................
Fastener Removal And Installation328................................................................................................................................................................
Body Cowling Cover And Lower Bracket Cover330................................................................................................................................................................
Inner Under Cowling330................................................................................................................................................................
Under Cowling330................................................................................................................................................................
Body Cowling331................................................................................................................................................................
Air Intake Pipe332................................................................................................................................................................
Cowling Brace332................................................................................................................................................................
Front Seat332................................................................................................................................................................
Fuel Tank Lower Side Cover332................................................................................................................................................................
Rear Seat/seat Tail Cover333................................................................................................................................................................
Frame Cover333................................................................................................................................................................
Front Wheel334................................................................................................................................................................
Suspension Setting352................................................................................................................................................................
Steering Damper353................................................................................................................................................................
Steering Tension Adjustment360................................................................................................................................................................
Rear Wheel365................................................................................................................................................................
Rear Shock Absorber373................................................................................................................................................................
Rear Shock Absorber Scrapping Procedure376................................................................................................................................................................
Final Inspection And Adjustment388................................................................................................................................................................
Front Brake389................................................................................................................................................................
Brake Pad Replacement390................................................................................................................................................................
Brake Fluid Replacement391................................................................................................................................................................
Caliper Removal392................................................................................................................................................................
Caliper Disassembly392................................................................................................................................................................
Caliper Inspection393................................................................................................................................................................
Caliper Reassembly393................................................................................................................................................................
Caliper Installation394................................................................................................................................................................
Brake Disc Inspection395................................................................................................................................................................
Master Cylinder Removal And Disassembly396................................................................................................................................................................
Master Cylinder Inspection397................................................................................................................................................................
Rear Brake400................................................................................................................................................................
Caliper Removal And Disassembly402................................................................................................................................................................
Service Limit404................................................................................................................................................................
Tire And Wheel410................................................................................................................................................................
Tire Removal410................................................................................................................................................................
Valve Inspection411................................................................................................................................................................
Tire Installation412................................................................................................................................................................
Balancer Weight Installation413................................................................................................................................................................
Drive Chain Cutting414................................................................................................................................................................
Drive Chain Connecting415................................................................................................................................................................
Cautions In Servicing420................................................................................................................................................................
Connecting The Battery421................................................................................................................................................................
Semi-conductor Equipped Part421................................................................................................................................................................
Wiring Procedure421................................................................................................................................................................
Location Of Electrical Components423................................................................................................................................................................
Charging System425................................................................................................................................................................
Troubleshooting429................................................................................................................................................................
Starter Motor Removal430................................................................................................................................................................
Starter Motor Disassembly431................................................................................................................................................................
Starter Motor Inspection431................................................................................................................................................................
Starter Motor Reassembly432................................................................................................................................................................
Starter Relay Inspection433................................................................................................................................................................
Side Stand/ignition Interlock System Parts Inspection434................................................................................................................................................................
Ignition System437................................................................................................................................................................
Immobilizer (except For E)438................................................................................................................................................................
Combination Meter446................................................................................................................................................................
Starter Relay454................................................................................................................................................................
Turn Signal/side-stand Relay454................................................................................................................................................................
Fuel Pump Relay454................................................................................................................................................................
Cooling Fan Relay454................................................................................................................................................................
Ignition Switch Removal455................................................................................................................................................................
Ignition Switch Installation455................................................................................................................................................................
Switches Inspection456................................................................................................................................................................
Initial Charging457................................................................................................................................................................
Recharging Operation459................................................................................................................................................................
Fi System Malfunction Code And Defective Condition461................................................................................................................................................................
Radiator (cooling System)471................................................................................................................................................................
Wiring Harness Routing476................................................................................................................................................................
Wiring Harness, Cable And Hose Routing476................................................................................................................................................................
Ho2 Sensor Harness Routing (for E)479................................................................................................................................................................
Cable Routing480................................................................................................................................................................
Fuel Tank Hose Routing481................................................................................................................................................................
Cooling System Hose Routing482................................................................................................................................................................
Front Brake Hose Routing483................................................................................................................................................................
Rear Brake Hose Routing484................................................................................................................................................................
Cowling Installation485................................................................................................................................................................
Frame Cover Installation486................................................................................................................................................................
Seat Lock Cable Routing487................................................................................................................................................................
Rear Fender Installation487................................................................................................................................................................
Side-stand Installation489................................................................................................................................................................
Front Footrest Installation490................................................................................................................................................................
Rear View Mirror Installation491................................................................................................................................................................
Special Tools492................................................................................................................................................................
Tightening Torque496................................................................................................................................................................
Fi System And Intake Air System497................................................................................................................................................................
Tightening Torque Chart499................................................................................................................................................................
Service Data500................................................................................................................................................................
Emission Control Systems511................................................................................................................................................................
Fuel Injection System511................................................................................................................................................................
Crankcase Emission Control System512................................................................................................................................................................
Noise Emission Control System514................................................................................................................................................................
Pair Reed Valve515................................................................................................................................................................
Pcv Hose515................................................................................................................................................................
Pair Control Solenoid Valve516................................................................................................................................................................

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