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Suzuki GSX R 750 2006-2007 Service Repair Manual

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The Suzuki GSX-R750, covering the 2006 and 2007 model years, represents a pinnacle of supersport motorcycle engineering. This machine is celebrated for its exceptional power-to-weight ratio and precise handling, making...
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Suzuki GSX R 750 2006-2007 Service Repair Manual
The Suzuki GSX-R750, covering the 2006 and 2007 model years, represents a pinnacle of supersport motorcycle engineering. This machine is celebrated for its exceptional power-to-weight ratio and precise handling, making it a favorite among enthusiast riders and track day participants. Its design emphasizes performance, featuring a technologically advanced inline-four engine that delivers exhilarating acceleration and a chassis engineered for agility and responsiveness. The GSX-R750 embodies dedication to creating high-performance sportbikes that offer a thrilling riding experience on both the road and the racetrack, consistently earning praise for its capability and competitive edge in its class. This comprehensive Factory Service Repair Manual provides in-depth guidance for the maintenance and repair of your Suzuki GSX-R750. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, and the electrical system. The manual also outlines routine maintenance tasks, troubleshooting steps for common issues, component replacement, and rebuilding procedures. With clear illustrations, exploded views, and technical specifications, this manual is an indispensable resource for owners, technicians, and mechanics aiming to preserve the optimal performance and longevity of their 2006-2007 Suzuki GSX-R750.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSX-R750
Years Covered:
2006-2007
👋 Introduction
Market Position
Model Segment:
Supersport / Hyperbike
Intended User:
Enthusiast riders, track day participants, performance-oriented road riders.
Competitive Analysis
Key Competitors 2006 2007:
Yamaha YZF-R6, Kawasaki Ninja ZX-6R, Honda CBR600RR, Ducati 749/999 (though slightly different class).
Key Features
Performance Focus:
Designed for maximum power-to-weight ratio and agile handling, making it a track-day favorite.
Technological Advancements:
Represents Suzuki's commitment to inline-four engine technology and advanced chassis design for its era.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly including cylinder head, pistons, crankshaft, camshafts, valve train, lubrication system, and cooling system.
Fuel System:
Fuel injection system (EFI) diagnostics, injector service, throttle body inspection and cleaning, fuel pump operation, and fuel pressure testing.
Ignition System:
Ignition system components, coil testing, spark plug specifications, ignition timing, and electronic ignition control unit (ECU) diagnostics.
Transmission And Drivetrain:
Clutch operation and adjustment, gearbox inspection, gear shift mechanism, final drive chain and sprockets maintenance, and bearing checks.
Suspension:
Front fork disassembly, servicing, and adjustment (compression, rebound, preload); rear shock absorber inspection and replacement; linkage and bearing maintenance.
Brakes:
Brake caliper inspection, pad replacement, rotor resurfacing/replacement, brake fluid bleeding procedures, master cylinder service, and ABS system diagnostics (if equipped).
Electrical System:
Wiring diagrams, lighting system, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), instrumentation, sensors, and ECU troubleshooting.
Chassis And Frame:
Frame inspection, swingarm removal and installation, steering head bearings, wheel bearing service, and general chassis component checks.
Bodywork And Fairings:
Fairing removal and installation procedures, seat assembly, fuel tank removal, and general body component servicing.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug checks, brake fluid level checks, and coolant level checks.
Troubleshooting:
Diagnostic flowcharts for common starting, running, electrical, and performance issues based on symptoms.
Component Replacement:
Detailed step-by-step instructions for replacing major components like exhaust systems, battery, tires, and control cables.
Rebuilding Procedures:
Comprehensive guides for engine internal rebuilds, including torque specifications, clearances, and assembly sequences.
Calibration And Adjustment:
Valve clearance adjustments, throttle position sensor (TPS) calibration, idle speed settings, and suspension sag adjustment.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics for EFI system faults, sensor readings, and error code interpretation (if applicable for the era).
Repair Scope:
Covers everything from basic maintenance to complete engine and transmission overhauls, including specialized tools required.
Diagrams And Illustrations:
High-quality exploded view diagrams and clear procedural illustrations for most repair and maintenance tasks.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Image Quality:
High-resolution, optimized for clarity.
Printable:
Yes
Software Recommendation:
Adobe Acrobat Reader or compatible PDF viewer.
Binding Type
Physical Format:
Digital (PDF)
Paper Type
Digital Medium:
Electronic document
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, 16-valve Inline-4
Displacement:
749 cc (45.7 cu. in.)
Bore X Stroke:
72.0 mm x 46.0 mm (2.83 in. x 1.81 in.)
Compression Ratio:
12.5:1
Performance
Horsepower Approx:
135.1 hp (99.3 kW) @ 12,000 rpm (Rear Wheel)
Torque Approx:
61.7 lb-ft (83.7 Nm) @ 10,500 rpm (Rear Wheel)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Twin Fuel Injectors per cylinder
Fuel Type:
Unleaded gasoline, Octane rating 91 or higher (96 RON or higher)
Lubrication System
Oil Type Recommendation:
SAE 10W-40, API SG+, JASO MA certified motorcycle oil.
Cooling System
Coolant Type:
Suzuki Long Life Coolant (or equivalent ethylene glycol-based antifreeze with distilled water, 50/50 mix).
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed, return type
Clutch Type:
Wet, multi-plate, cable operated
Features
Gear Ratios:
Provided within manual, typical ratios: 1st: 2.750, 2nd: 2.000, 3rd: 1.700, 4th: 1.450, 5th: 1.273, 6th: 1.125
Final Drive:
RK525SH (or equivalent) O-ring sealed chain, 15T front sprocket, 47T rear sprocket.
📐 Dimensions
Exterior
Overall Length:
Approx. 2,030 mm (79.9 in.)
Overall Width:
Approx. 715 mm (28.1 in.)
Overall Height:
Approx. 1,135 mm (44.7 in.)
Wheelbase:
Approx. 1,405 mm (55.3 in.)
Ground Clearance:
Approx. 130 mm (5.1 in.)
Weights
Dry Weight:
Approx. 163 kg (359 lbs)
Curb Weight:
Approx. 190 kg (419 lbs) (fully fueled)
Front Tire Size:
120/70ZR17 M/C (58W) tubeless
Rear Tire Size:
180/55ZR17 M/C (73W) tubeless
Wheelbase Type:
Cast aluminum alloy
Fuel Tank Capacity:
17.0 L (4.5 US gal; 3.7 Imp gal)
🛡️ Safety Features
Ratings
Safety Features Era:
Focus on chassis rigidity, responsive braking, and rider ergonomics for control. ABS was generally not standard or available on this model.
Active Features
Braking System:
Dual 320mm petal-disc front brakes with 4-piston calipers, Single 220mm petal-disc rear brake with 2-piston caliper.
Suspension Design:
Front: Inverted telescopic, coil spring, oil damped. Rear: Link type, coil spring, oil damped, spring preload and rebound damping adjustable.
Passive Features
Frame Construction:
Aluminum alloy twin-spar frame, designed for high rigidity and light weight.
💡 Technology Features
Infotainment
Instrumentation:
Digital LCD speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and indicator lights. Backlit for night visibility.
Driver Assistance
ABS Availability:
ABS was not a standard feature on the 2006-2007 GSX-R750, and was rarely an option, making it a pure, unassisted braking experience.
Connectivity
Diagnostic Port:
Likely features a diagnostic connector for basic ECU readouts or requires specialized Suzuki diagnostic tools for advanced troubleshooting.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first. (Refer to manual for specific conditions).
Air Filter Inspection:
Inspect every 6,000 km (3,700 miles), clean or replace as needed. Replace every 18,000 km (11,200 miles).
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Check every 24,000 km (15,000 miles).
Chain Lubrication:
Lubricate every 1,000 km (600 miles) or after riding in rain/wet conditions.
Chain Adjustment:
Adjust chain slack to 20-30 mm (0.79-1.18 in.) every 1,000 km (600 miles).
Fluid Specifications
Engine Oil Capacity:
3.4 L (3.6 US qt) without filter change; 3.6 L (3.8 US qt) with filter change.
Coolant Capacity:
Approx. 1.8 L (1.9 US qt)
Brake Fluid Type:
DOT 4
Fork Oil Type And Volume:
SAE 10W fork oil; 432 ml (14.6 US oz) per fork leg. (Refer to manual for precise specification).
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, wheel bearings, and brake pads due to high-performance use.
Potential Electrical Issues:
Regulator/rectifier failure (common across many sportbikes of this era), battery charging issues.
Engine Considerations:
Proper and timely maintenance is critical to prevent issues with the high-strung inline-four engine. Valve clearances and oil changes are paramount.
📚 Vehicle History
Brand Heritage
Suzuki Motorcycle Legacy:
Suzuki has a long and storied history in motorcycle racing and performance, particularly with its GSX-R line, which revolutionized the supersport category.
Model Evolution
Gsx R750 Lineage:
The GSX-R750 has been a benchmark in the 750cc class since its inception, evolving through multiple generations to incorporate technological advancements and performance improvements.
K6 K7 Generation:
The 2006-2007 (K6/K7) models represent a significant update, featuring a more compact engine, revised chassis, and improved aerodynamics, building upon the success of previous generations.
Production
Manufacturing Location:
Primarily Japan, but components may be sourced globally.
🏆 Awards & Recognition
Recognitions
Sportbike Category:
The GSX-R series consistently receives accolades from motorcycle publications for its performance, handling, and track capability, often ranking highly in shootouts for its class.
Ratings
Performance Reviews:
Praised for its potent engine, sharp handling, and competitive pricing compared to some European rivals.
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