Suzuki Gixxer GSXR 600 2006 2007 Workshop Service Manual

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UGS: 81526

Mots clés: 2006 2007 Gixxer GSXR 600 Misc Motorcycle Motorcycles Suzuki

Variantes de produits

Description

The Suzuki GSX-R600, often affectionately known as the "Gixxer," is a celebrated supersport motorcycle that has consistently defined performance and handling in the 600cc class. Produced between 2006 and 2007, this K6/K7 generation model builds upon Suzuki's rich racing heritage, offering a potent inline-four, liquid-cooled engine with a Dual Throttle Valve (SDTV) system for refined throttle response. Its lightweight twin-spar aluminum alloy frame, aggressive aerodynamic fairing design, and advanced suspension contribute to its exceptional agility and stability, making it a formidable machine for both spirited road riding and track day enthusiasts. This comprehensive Workshop Service Manual provides detailed technical information and procedures for the Suzuki GSX-R600 (K6/K7). It covers all essential aspects of the motorcycle, including complete engine mechanicals, fuel and ignition systems, cooling, transmission, drivetrain, suspension, brakes, and electrical systems. The manual offers step-by-step instructions for routine maintenance, troubleshooting common issues, and performing in-depth repairs and overhauls. With detailed specifications, torque values, and clear wiring diagrams, this resource is an indispensable tool for professional technicians and experienced DIY owners seeking to maintain, repair, and optimize their GSX-R600.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX-R600

Nickname:

Gixxer

Platform Code:

K6/K7

👋 Introduction

Market Position

Category:

Supersport Motorcycle

Segment:

600cc Class

Competitive Analysis

Key Competitors:

Yamaha YZF-R6, Kawasaki Ninja ZX-6R, Honda CBR600RR

Key Features

Engine Type:

Inline-Four, Liquid-Cooled, DOHC

Frame Type:

Twin-spar aluminum alloy

Aerodynamics:

Sharp, aggressive fairing design for enhanced airflow and stability.

Electronics:

Advanced EFI, potentially S-DMS (Suzuki Dual Throttle Valve System) for improved throttle response.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

Page Count:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, inspection, and assembly of the 4-cylinder engine block, crankshaft, pistons, connecting rods, cylinder head, valves, camshafts, timing system, and lubrication system.

Fuel System:

Detailed coverage of the electronic fuel injection (EFI) system, throttle bodies, fuel pump, fuel pressure regulator, injectors, and fuel tank.

Ignition System:

Information on ignition coils, spark plugs, ECU control, and timing.

Cooling System:

Radiator, cooling fan, water pump, thermostat, hoses, and coolant specifications.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly, inspection, and reassembly; final drive inspection.

Suspension System:

Front telescopic forks (including damping and spring preload adjustments), rear monoshock absorber, linkage system, and wheel bearing service.

Brake System:

Front and rear disc brakes, hydraulic system, brake fluid specifications, caliper servicing, master cylinder overhaul, and pad replacement.

Electrical System:

Battery, charging system (stator, rectifier/regulator), starter motor, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays, and instrument panel.

Chassis And Frame:

Frame inspection, steering head bearing service, and swingarm maintenance.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank, and minor body component servicing.

Procedures Included

Maintenance:

Routine checks, fluid changes (oil, coolant, brake fluid), filter replacements, chain adjustment and lubrication, spark plug service, and general inspection procedures.

Troubleshooting:

Diagnostic procedures for common problems related to starting, running, electrical systems, and performance issues. Includes symptom-based troubleshooting charts.

Repair And Overhaul:

Detailed step-by-step instructions for dismantling, inspecting, repairing, and reassembling major mechanical and electrical components.

Specifications And Measurements:

Torque specifications for all fasteners, critical clearances (e.g., valve lash, piston ring gap), bore and stroke dimensions, and electrical system values.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for the entire motorcycle, color-coded for clarity.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine rebuild)

Target Audience:

Professional motorcycle technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Yes (assumed for professional PDF)

Print Quality

Print Quality:

High-resolution (suitable for printing)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-Four, liquid-cooled, DOHC, 16 valves

Displacement:

599 cc

Bore X Stroke:

67.0 mm x 42.5 mm

Compression Ratio:

12.8:1

Performance

Horsepower:

Approx. 120-125 hp (at crankshaft, may vary by region/tuning)

Torque:

Approx. 68-70 Nm (at crankshaft, may vary by region/tuning)

Fuel System

Fuel Delivery:

Fuel Injection with Dual Throttle Valve (SDTV) system

Fuel Type:

Unleaded Premium Gasoline

Lubrication

Oil Type:

API SG, SH, SJ, SL grade, SAE 10W-40 or 10W-50 (refer to manual for specific recommendations)

Oil Capacity:

Approx. 3.4 L (with filter change)

🔧 Transmission

Standard

Type:

Constant mesh 6-speed, return type

Clutch:

Wet, multi-plate, back-torque limiter

Features

Gear Ratios:

Refer to manual for specific gear ratios.

Drivetrain

Final Drive:

Sealed O-ring type, 525 chain

📐 Dimensions

Exterior

Overall Length:

Approx. 2,030 mm (80.0 in)

Overall Width:

Approx. 720 mm (28.3 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. 162 kg (357 lbs)

Curb Weight:

Approx. 187 kg (412 lbs) (fully fueled)

Fuel Tank Capacity:

17.0 L (4.5 US gal)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle specific safety ratings not typically provided in the same way as cars)

Active Features

Braking System:

Dual 310 mm petal discs with radial-mount monobloc calipers (front), Single 220 mm petal disc with single-piston caliper (rear).

Suspension Adjustability:

Adjustable front forks (preload, compression, rebound) and rear shock (preload, rebound).

Passive Features

Lighting:

Multi-reflector halogen headlight, LED taillight.

Tires:

Sport-oriented radial tires. Front: 120/70ZR17 M/C (58W), Rear: 180/55ZR17 M/C (73W).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic LCD instrument cluster)

Driver Assistance

Rider Aids:

None (ABS was typically an optional feature or introduced later in other models/regions).

Connectivity

Connectivity Features:

Engine Management

ECU Features:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and idle speed control. Features Suzuki Dual Throttle Valve (SDTV) system for improved power delivery.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning Inspection:

Every 12,000 km (7,500 miles).

Spark Plug Replacement:

Every 24,000 km (15,000 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain.

Brake Fluid Replacement:

Every 2 years or as needed.

Coolant Replacement:

Every 3 years or as needed.

Valve Lash Inspection:

Every 24,000 km (15,000 miles).

Fluid Specifications

Engine Oil:

SAE 10W-40 or 10W-50 API SG, SH, SJ, SL (Suzuki brand recommended)

Coolant:

Suzuki Super Long Life Coolant or equivalent ethylene glycol-based coolant (50% mixture with distilled water).

Brake Fluid:

DOT 4.

Known Issues

Common Issues:

Occasional issues might include regulator/rectifier failure (common across many Japanese bikes of this era), potential stator issues, and normal wear-and-tear on clutch plates and suspension components with high mileage.

📚 Vehicle History

Brand Heritage

Heritage:

Suzuki has a long and successful history in motorcycle racing, particularly in the 600cc supersport class, with numerous championship wins contributing to the GSX-R line's reputation.

Model Evolution

Generation K6 K7:

The 2006-2007 GSX-R600 represented a significant evolution from the previous generation (K4/K5), featuring a new chassis, updated engine for increased power and responsiveness, and revised suspension geometry.

Production

Manufacturing Location:

Japan (Primary)

Production Years:

2006-2007

🏆 Awards & Recognition

Recognitions

Model Recognition:

The GSX-R600 has consistently been praised by motorcycle journalists and riders for its performance, handling, and race-bred pedigree.

Ratings

Track Performance:

Highly regarded for its track day capability and competitive nature in its class.