Suzuki Gixxer GSXR 600 2004 2005 Workshop Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 81525

Mots clés: 2004 2005 465 Case Construction Gixxer GSXR 600 Motorcycle Skid Steer Loaders Suzuki

Variantes de produits

Description

The Suzuki GSXR600, specifically the K4/K5 generation produced between 2004 and 2005, represents a significant evolution in the middleweight supersport motorcycle class. Known for its potent 599 cc four-stroke, liquid-cooled engine, this model delivers approximately 110-115 horsepower, channeled through a precise 6-speed transmission. Its engineering prowess is evident in the advanced aluminum twin-spar frame, inverted telescopic front forks, and linkage-type rear suspension, all contributing to exceptional handling and rider feedback. Designed for performance-oriented riding, the GSXR600 (Gixxer) offers a dynamic and engaging experience, building upon Suzuki's rich heritage in motorcycle racing. This comprehensive workshop service manual is your essential guide for the repair and overhaul of the Suzuki GSXR600 (K4/K5). Covering a wide array of systems, including detailed procedures for engine disassembly and reassembly, fuel and ignition systems, lubrication, electrical components, transmission, suspension, brakes, and more, this manual ensures you have the information needed for meticulous maintenance. It provides step-by-step instructions for routine servicing, component removal and installation, troubleshooting common issues, and references special tools. With its in-depth coverage, this 465-page English-language manual is an indispensable resource for both professional technicians and dedicated enthusiasts seeking to maintain and optimize their GSXR600.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSXR600 (Gixxer)

Year:

2004-2005

Codes

Chassis Code:

K4/K5

👋 Introduction

Market Position

Description:

The Suzuki GSXR600 (K4/K5 generation) was a highly regarded middleweight supersport motorcycle known for its performance, handling, and race-derived technology. This manual targets owners and technicians aiming for precise maintenance and repair.

Competitive Analysis

Competitors:

Honda CBR600RR, Yamaha R6, Kawasaki ZX-6R

Key Features

Advantage:

Provides detailed, manufacturer-specific information for optimal servicing and repair, enabling professional-quality results.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and Overhaul

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, disassembly, reassembly, tuning

Fuel System:

Carburetor settings, fuel pump, lines, injectors (if applicable)

Ignition System:

Ignition timing, spark plugs, coils, CDI unit

Lubrication System:

Oil pump, oil filter, oil passages, oil change procedures

Exhaust System:

Muffler, catalytic converter (if applicable), exhaust headers

Electrical System:

Wiring diagrams, charging system, lighting, starter, battery

Body:

Fairings, seat, fuel tank, fenders, mirrors

Transmission:

Gearbox disassembly, inspection, reassembly, clutch

Suspension:

Front fork disassembly, adjustment, rear shock absorber, linkages

Brakes:

Brake caliper overhaul, master cylinder, brake lines, pad replacement

Wheels And Tires:

Wheel bearing replacement, tire pressure, wheel balance

Cooling System:

Radiator, cooling fan, coolant hoses, thermostat

Frame And Steering:

Steering head bearing replacement, frame inspection

Proprietary Components:

Includes instructions for proprietary Suzuki components and references for third-party parts if integrated.

Procedures Included

Maintenance:

Routine servicing, tune-ups, fluid changes, filter replacements

Removal Installation:

Detailed procedures for component removal and installation

Assembly Disassembly:

Step-by-step guides for major component overhauls

Troubleshooting:

Diagnostic procedures for common issues

Special Tool Identification:

References to specific Suzuki special tools and their application

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIYers

Diagnostic Capabilities:

Includes troubleshooting guides for electrical and mechanical issues

Manual Type

Purpose:

To enable technicians to perform accurate repairs and maintenance, ensuring optimal vehicle performance and longevity.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF

Searchability:

Searchable text for quick information retrieval

Print Quality

Printable:

Binding Type

Binding:

Digital (PDF Download)

Paper Type

Paper Type:

Not Applicable (Digital)

⚙️ Engine Specifications

Primary Engine

Type:

90° V-twin, Four-stroke, Liquid-cooled

Displacement:

599 cc

Bore X Stroke:

72.0 mm x 48.6 mm

Valve Train:

DOHC, 16 valves (4 per cylinder)

Compression Ratio:

12.4:1

Starting System:

Electric starter

Performance

Horsepower:

Approx. 110-115 hp (at crank)

Torque:

Approx. 48-50 lb-ft (at crank)

Fuel System

Induction:

Mikuni BSR32 flat-slide carburetors

Fuel Capacity:

4.4 US gal (16.5 L)

Lubrication System

Oil Capacity With Filter:

3.2 US qt (3.0 L)

Cooling System

Coolant Type:

Suzuki Super Long Life Coolant (or equivalent)

Ignition

Ignition Type:

Electronic ignition (CDI)

Exhaust

Exhaust System Type:

2-into-1-into-2 stainless steel

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Features

Clutch:

Wet multi-plate

Final Drive:

O-ring sealed chain

Gear Ratios:

Detailed in manual (specific ratios for each gear)

Fluid Specifications

Transmission Oil Type:

API GL-4 SAE 10W-40 motorcycle gear oil

📐 Dimensions

Exterior

Length:

2045 mm (80.5 in)

Width:

715 mm (28.1 in)

Height:

1130 mm (44.5 in)

Wheelbase:

1405 mm (55.3 in)

Ground Clearance:

130 mm (5.1 in)

Seat Height:

830 mm (32.7 in)

Weights

Dry Weight:

163 kg (359 lbs)

Curb Weight:

187 kg (412 lbs)

Weight Distribution:

Front: 52%, Rear: 48% (approx.)

Payload Capacity:

Not specified (Designed for solo rider)

Wheels And Tires

Front Tire:

120/70ZR17M/C (58W)

Rear Tire:

180/55ZR17M/C (73W)

Front Wheel:

3.50 x 17

Rear Wheel:

5.50 x 17

🛡️ Safety Features

Active Features

Braking System:

Dual hydraulic disc front, single hydraulic disc rear

Front Brakes:

2x 300mm discs with 4-piston calipers

Rear Brakes:

1x 220mm disc with 2-piston caliper

Front Suspension:

Inverted telescopic, coil spring, oil damped

Rear Suspension:

Linkage type, spring loaded, oil damped

Passive Features

Frame Type:

Aluminum twin-spar frame

💡 Technology Features

Infotainment

Features:

N/A (Focus on performance, not infotainment)

Driver Assistance

Features:

N/A (No electronic rider aids like traction control)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (4,800 km) or 6 months

Air Filter Cleaning:

Every 3,000 miles (4,800 km)

Spark Plug Replacement:

Every 10,000 miles (16,000 km)

Chain Maintenance:

Inspect and lubricate every 500 miles (800 km)

Coolant Flush:

Every 2 years

Fluid Specifications

Engine Oil Grade:

10W-40, JASO MA certified

Brake Fluid:

DOT 4

Coolant:

Suzuki Super Long Life Coolant or equivalent 50/50 mix

Known Issues

Common Problems:

Occasional issues with stator failure, clutch wear under aggressive use, and carburetor synchronization drift. Manual provides detailed diagnostics.

Torque Specifications

Importance:

Crucial for engine and chassis components; the manual details specific torque values for all fasteners.

📚 Vehicle History

Brand Heritage

Heritage:

Suzuki has a long and successful history in motorcycle racing, particularly in the 500cc and MotoGP classes, which heavily influences its GSXR line.

Model Evolution

K4 K5 Era:

This generation refined the previous GSXR600, featuring improved aerodynamics, a revised chassis for better handling, and updated engine components for increased power delivery and responsiveness.

Production

Manufacturing Location:

Japan