- •HOW TO USE THIS MANUAL
- •TO LOCATE WHAT YOU ARE LOOKING FOR:
- •COMPONENT PARTS AND WORK TO BE DONE
- •SYMBOL
- •ABBREVIATIONS USED IN THIS MANUAL
- •01 GENERAL INFORMATION
- •COUNTRY AND AREA CODES
- •WARNING/CAUTION/NOTE
- •GENERAL PRECAUTIONS
- •SUZUKI GSX-R600K6 (’06-MODEL)
- •SERIAL NUMBER LOCATION
- •FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
- •BREAK-IN PROCEDURES
- •CYLINDER IDENTIFICATION
- •INFORMATION LABELS
- •SPECIFICATIONS
- •02 PERIODIC MAINTENANCE
- •PERIODIC MAINTENANCE SCHEDULE
- •MAINTENANCE AND TUNE-UP PROCEDURES
- •COMPRESSION PRESSURE CHECK
- •SDS CHECK
- •03 ENGINE
- •ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
- •ENGINE REMOVAL AND INSTALLATION
- •ENGINE DISASSEMBLY
- •ENGINE REASSEMBLY
- •04 FI SYSTEM DIAGNOSIS
- •PRECAUTIONS IN SERVICING
- •FI SYSTEM TECHNICAL FEATURES
- •ECM TERMINAL
- •SELF-DIAGNOSIS FUNCTION
- •FAIL-SAFE FUNCTION
- •FI SYSTEM TROUBLESHOOTING
- •SENSORS
- •05 FUEL SYSTEM AND THROTTLE BODY
- •FUEL DELIVERY SYSTEM
- •FUEL SYSTEM
- •THROTTLE BODY
- •06 EXHAUST SYSTEM
- •EXHAUST SYSTEM
- •EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)
- •07 COOLING AND LUBRICATION SYSTEM
- •ENGINE COOLANT
- •COOLING CIRCUIT
- •COOLING FAN
- •ECT SENSOR
- •THERMOSTAT
- •WATER PUMP
- •LUBRICATION SYSTEM
- •08 CHASSIS
- •EXTERIOR PARTS
- •FRONT WHEEL
- •FRONT FORK
- •STEERING DAMPER
- •STEERING
- •HANDLEBARS
- •REAR WHEEL
- •REAR SHOCK ABSORBER
- •REAR SUSPENSION
- •FRONT BRAKE
- •REAR BRAKE
- •TIRE AND WHEEL
- •DRIVE CHAIN
- •09 ELECTRICAL SYSTEM
- •CAUTIONS IN SERVICING
- •LOCATION OF ELECTRICAL COMPONENTS
- •CHARGING SYSTEM
- •STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
- •IGNITION SYSTEM
- •COMBINATION METER
- •LAMPS
- •RELAYS
- •BATTERY
- •10 SERVICING INFORMATION
- •TROUBLESHOOTING
- •WIRING HARNESS, CABLE AND HOSE ROUTING
- •TIGHTENING TORQUE
- •SERVICE DATA
- •11 EMISSION CONTROL INFORMATION
- •EMISSION CONTROL SYSTEMS
- •PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION
- •PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
- •HO2 SENSOR INSPECTION (For E-02, 19)
- •12 WIRING DIAGRAM
ELECTRICAL SYSTEM 9-1
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING |
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CONNECTOR ........................................................................................ |
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COUPLER.............................................................................................. |
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CLAMP .................................................................................................. |
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FUSE...................................................................................................... |
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SEMI-CONDUCTOR EQUIPPED ...............................................PART |
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BATTERY .............................................................................................. |
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CONNECTING THE BATTERY............................................................. |
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WIRING PROCEDURE.......................................................................... |
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USING THE MULTI-CIRCUIT .................................................TESTER |
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LOCATION OF ELECTRICAL .........................................COMPONENTS |
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CHARGING SYSTEM ................................................................................. |
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TROUBLESHOOTING |
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INSPECTION |
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STARTER SYSTEM AND SIDE-STAND/ |
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IGNITION INTERLOCK SYSTEM |
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TROUBLESHOOTING........................................................................... |
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STARTER MOTOR REMOVAL............................................................. |
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STARTER MOTOR DIS .....................................................SSE BLY |
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STARTER MOTOR INSPECTION......................................................... |
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STARTER MOTOR RE ......................................................SSEMBLY |
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STARTER RELAY INSPECTION ..........................................................
SIDE STAND/IGNITION INTERLOCK
SYSTEM PARTS INSPECTION ............................................................
IGNITION SYSTEM .....................................................................................
IMMOBILIZER (Except for E-03, 28, 33)..............................................
TROUBLESHOOTING...........................................................................
INSPECTION .........................................................................................
COMBINATION METER .............................................................................
DESCRIPTION.......................................................................................
REMOVAL AND DISASSEMBLY .........................................................
INSPECTION .........................................................................................
LAMPS ........................................................................................................
HEADLIGHT, BRAKE LIGHT/TAILLIGHT,
LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT.........................
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9-12 |
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9-12 |
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9-13 |
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9-14 |
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9-14 |
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9-15 |
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9-16 |
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9-17 |
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9-20 |
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9-21 |
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9-23 |
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9-25 |
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9-29 |
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9-29 |
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9-30 |
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9-31 |
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9-35 |
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9-35 |
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9-2 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONTENTS
RELAYS ...................................................................................................... |
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9-37 |
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TURN SIGNAL/SIDE-STAND RELAY .................................................. |
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9-37 |
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STARTER RELAY ................................................................................. |
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FUEL PUMP RELAY ............................................................................. |
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9-37 |
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COOLING FAN RELAY......................................................................... |
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9-37 |
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IGNITION SWITCH REMOVAL ............................................................. |
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9-38 |
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IGNITION SWITCH INSTALLATION..................................................... |
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9-38 |
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SWITCHES INSPECTION ..................................................................... |
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9-39 |
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BATTERY .................................................................................................... |
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9-40 |
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SPECIFICATIONS ................................................................................. |
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9-40 |
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INITIAL CHARGING .............................................................................. |
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9-40 |
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SERVICING ........................................................................................... |
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9-42 |
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RECHARGING OPERATION |
9-42 |
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ELECTRICAL SYSTEM 9-3
CAUTIONS IN SERVICING
CONNECTOR
•When connecting a connector, be sure to push it in until a click is felt.
•Inspect the connector for corrosion, contamination and breakage in its cover.
COUPLER |
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Click |
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• With a lock type coupler, be sure to release the lock when dis- |
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connecting, and push in fully to engage the lock when con- |
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necting. |
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• When disconnecting the coupler, be sure to hold the coupler |
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itself and do not pull the lead wires. |
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• Inspect each terminal on the coupler for being loose or bent. |
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• Inspect each terminal for corrosion and contamination. |
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CLAMP |
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• Clamp the wire harness at such positions as indicated in |
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CORRECT |
INCORRECT |
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“WIRING HARNESS ROUTING”. ( M10-17 to -20) |
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• Bend the clamp properly so that the wire harness is clamped |
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securely. |
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• In clamping the wire harness, use care not to allow it to hang |
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down. |
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• Do not use wire or any other substitute for the band type |
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clamp. |
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FUSE
•When a fuse blows, always investigate the cause to correct it and then replace the fuse.
•Do not use a fuse of a different capacity.
•Do not use wire or any other substitute for the fuse.
9-4 ELECTRICAL SYSTEM
SEMI-CONDUCTOR EQUIPPED PART |
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• Be careful not to drop the part with a semi-conductor built in |
INCORRECT |
such as a ECM. |
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•When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part.
BATTERY
• The MF battery used in this motorcycle does not require main- |
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tenance (e.g., electrolyte level inspection, distilled water |
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replenishment). |
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• During normal charging, no hydrogen gas is produced. How- |
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ever, if the battery is overcharged, hydrogen gas may be pro- |
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duced. Therefore, be sure there are no fire or spark sources |
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(e.g., short circuit) nearby when charging the battery. |
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• Be sure to recharge the battery in a well-ventilated and open |
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area. |
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• Note that the charging system for the MF battery is different |
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from that of a conventional battery. Do not replace the MF |
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battery with a conventional battery. |
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CONNECTING THE BATTERY |
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• When disconnecting terminals from the battery for disassem- |
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bly or servicing, be sure to disconnect the - battery lead |
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wire, first. |
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•When connecting the battery lead wires, be sure to connect the + battery lead wire, first.
•If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.
•After connecting the battery, apply a light coat of grease to the battery terminals.
•Install the cover over the + battery terminal.
WIRING PROCEDURE
•Properly route the wire harness according to the “WIRING HARENESS ROUTING” section. ( 10-17 to -20)
ELECTRICAL SYSTEM 9-5
USING THE MULTI-CIRCUIT TESTER
•Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester.
•If the voltage and current values are not known, begin measuring in the highest range.
•When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
•After using the tester, be sure to turn the switch to the OFF position.
09900-25008: Multi-circuit tester set
Before using the multi-circuit tester, read its instruction manual.
NOTE: |
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* When connecting the multi-circuit tester, use the needle |
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pointed probe to the back side of the lead wire coupler and |
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connect the probes of tester to them. |
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* Use the needle pointed probe to prevent the rubber of the |
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water proof coupler from damage. |
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09900-25009: Needle pointed probe set |
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