GSR600A.K7-Suppl (ID=1045).pdf

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GSR600A
USE THIS MANUAL WITH:
GSR600 SERVICE MANUAL (99500-36161-01E)
99501-36150-01E
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GSR600AK7 (’07-MODEL) 1
GSR600AK7 (’07-MODEL)
This manual describes service data, service specifications and ABS servicing procedures
which differ from those of the GSR600K7 (’07-model).
NOTE:
• Any differences between the GSR600K7 (’07-model) and GSR600AK7 (’07-model) in
specifications and service data are indicated with an asterisk mark (*).
• Please refer to the GSR600K6 (’06-model) service manual for details which are not
given in this manual.
CONTENTS
SPECIFICATIONS .............................................................................................. 3
INTRODUCTION OF ABS .................................................................................. 5
FRONT AND REAR WHEEL SPEED SENSORS..................................... 5
ABS CONTROL UNIT ............................................................................... 5
ABS CONTROL UNIT CALCULATING PROCESS.................................. 6
HYDRAULIC UNIT (HU)............................................................................ 7
FAIL-SAFE FUNCTION............................................................................. 8
SELF-DIAGNOSIS FUNCTION AND ABS INDICATOR LIGHT............... 8
CAUTIONS IN SERVICING ................................................................................ 9
ABS WIRING ............................................................................................. 9
FUSES ....................................................................................................... 9
BATTERY .................................................................................................. 9
ABS CONTROL UNIT/HU ......................................................................... 10
ABS INFORMATION ................................................................................. 10
TESTER..................................................................................................... 11
ABS COMPONENTS .......................................................................................... 12
ABS COMPONENTS LOCATION............................................................. 12
ABS COUPLER CONNECTION DIAGRAM ............................................. 13
ABS WIRING DIAGRAM........................................................................... 14
ABS CONTROL UNIT SYSTEM DIAGRAM ............................................. 15
ABS TROUBLESHOOTING ............................................................................... 16
ABS TROUBLESHOOTING DESCRIPTION ............................................ 16
TROUBLESHOOTING PROCEDURE ...................................................... 17
BASIC TROUBLESHOOTING DIAGRAM ................................................ 18
INFORMATION GATHERING ................................................................... 19
PRE-DIAGNOSIS INSPECTION ............................................................... 20
ABS INDICATOR LIGHT INSPECTION.................................................... 23
DTC (Diagnostic Trouble Code) OUTPUT.............................................. 27
DTC DELETING AND ABS OPERATION CHECK................................... 29
SDS CHECK.............................................................................................. 31
© COPYRIGHT SUZUKI MOTOR CORPORATION 2007
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2 GSR600AK7 (’07-MODEL)
GSR600AK7 (’07-MODEL)
CONTENTS
USE OF SDS DIAGNOSTIC PROCEDURES........................................... 32
USE OF SDS DIAGNOSIS RESET PROCEDURE .................................. 33
ACTIVE CONTROL INSPECTION ........................................................... 35
DTC TROUBLESHOOTING ..................................................................... 40
ABS COMPONENT REMOVAL, INSPECTION AND
INSTALLATION ........................................................................................ 62
COMBINATION METER ........................................................................... 70
WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION ............. 71
WIRE HARNESS ROUTING..................................................................... 71
FRONT BRAKE HOSE ROUTING ........................................................... 73
REAR BRAKE HOSE ROUTING.............................................................. 74
FRONT WHEEL SPEED SENSOR INSTALLATION ............................... 75
REAR FENDER HEAT SHIELD INSTALLATION .................................... 77
SPECIAL TOOLS............................................................................................... 78
TIGHTENING TORQUE ..................................................................................... 78
SERVICE DATA................................................................................................. 79
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
MODEL
CODE
COUNTRY or AREA
EFECTIVE FRAME NO.
GSR600A
E-02
E-19
E-24
U.K.
EU
Australia
JS1B9112100 100001 –
JS1B9112100 100001 –
JS1B9112300 100001 –
GSR600AUE
E-19
EU
JS1B9212100 100001 –
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GSR600AK7 (’07-MODEL) 3
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .......................................................................... 2 090 mm
Overall width ........................................................................... 795 mm
Overall height .......................................................................... 1 075 mm
Wheelbase .............................................................................. 1 440 mm
Ground clearance.................................................................... 130 mm
Seat height .............................................................................. 785 mm
Dry mass ................................................................................. * 188 kg
ENGINE
Type ........................................................................................ Four stroke, liquid-cooled, DOHC
Number of cylinders ................................................................ 4
Bore......................................................................................... 67.0 mm
Stroke...................................................................................... 42.5 mm
Displacement .......................................................................... 599 cm 3
Compression ratio ................................................................... 12.5 : 1
Fuel system............................................................................. Fuel injection
Air cleaner ............................................................................... Paper element
Starter system ......................................................................... Electric
Lubrication system .................................................................. Wet sump
Idle speed................................................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch ...................................................................................... Wet multi-plate type
Transmission........................................................................... 6-speed constant mesh
Gearshift pattern ..................................................................... 1-down, 5-up
Primary reduction ratio ............................................................ 1.926 (79/41)
Gear ratios, Low ................................................................... 2.785 (39/14)
2nd .................................................................... 2.000 (32/16)
3rd..................................................................... 1.600 (32/20)
4th ..................................................................... 1.363 (30/22)
5th ..................................................................... 1.208 (29/24)
Top.................................................................... 1.086 (25/23)
Final reduction ratio................................................................. 3.000 (48/16)
Drive chain .............................................................................. RK525SMOZ7Y, 114 links
4 GSR600AK7 (’07-MODEL)
CHASSIS
Front suspension .................................................................... Telescopic, coil spring, oil damped
Rear suspension ..................................................................... Link type, coil spring, oil damped
Front fork stroke...................................................................... 130 mm
Rear wheel travel .................................................................... 134 mm
Caster ..................................................................................... 25° 15’
Trail ......................................................................................... 104 mm
Steering angle......................................................................... 33° (right & left)
Turning radius ......................................................................... 2.9 m
Front brake.............................................................................. Disc brake, twin
Rear brake .............................................................................. Disc brake
Front tire size .......................................................................... 120/70ZR17M/C (58W), tubeless
Rear tire size........................................................................... 180/55ZR17M/C (73W), tubeless
ELECTRICAL
Ignition type............................................................................. Electronic ignition (Transistorized)
Ignition timing.......................................................................... 6° B.T.D.C. at 1 300 r/min
Spark plug............................................................................... NGK CR9E or DENSO U27ESR-N
Battery..................................................................................... 12 V 28.8 kC (8 Ah)/10 HR
Generator................................................................................ Three-phase A.C. generator
Main fuse ................................................................................ 30 A
Fuse ........................................................................................ 10/10/15/10/10/15/15/20 A
Headlight................................................................................. 12 V 60/55 W H4
Turn signal light....................................................................... 12 V 10 W
Brake light/Taillight.................................................................. LED
Position light............................................................................ 12 V 5 W × 2
Licence plate light ................................................................... 12 V 5 W
Speedometer light................................................................... LED
Tachometer light ..................................................................... LED
Neutral indicator light .............................................................. LED
High beam indicator light ........................................................ LED
Turn signal indicator light ........................................................ LED
Oil pressure/Engine coolant temperature indicator light ......... LED
Fuel injection indicator light..................................................... LED
Immobilizer indicator light ....................................................... LED
ABS indicator light................................................................... * LED
CAPACITIES
Fuel tank ................................................................................. 16.5 L
Engine oil, oil change ............................................................ 3 200 ml
with filter change.................................................. 3 600 ml
overhaul............................................................... 3 900 ml
Coolant.................................................................................... 2.8 L
These specifications are subject to change without notice.

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