Suzuki GSX-R600 Service & Parts Manual Set, 2005–2012 (P/N 99500-35100-01E)

The parts catalog’s exploded drawings are for parts identification, not assembly instructions; the service manual supplies the repair procedures and installation data.

The “2005-12” marking on the catalog cover is its December 2005 publication date, not 2005–2012 model-year coverage. No K7 supplement or later-model repair material is included.

U2/U3 identification: The service manual and parts catalog reverse the U2/U3 frame-number assignments. Confirm the exact variant before ordering region-specific parts.

PDF Text Search, Bookmarks and Wiring Detail

Search and diagram detail: Both PDFs have searchable text and embedded bookmarks. Some illustration labels in the service manual are not searchable. Small labels on the regional wiring diagrams require zooming.

ZIP download containing two printable English PDFs with 615 pages total. This includes 9 cover, introductory and publication pages in the service manual, and 11 cover, divider, photo, blank and imprint pages in the catalog.

Engine Overhaul, FI Diagnosis and Parts Identification

The following is a selection of covered topics, rather than a complete contents list. Additional subjects include PAIR emission-control inspection and battery servicing.

• Engine and drivetrain repair: Engine removal, disassembly and reassembly; cylinder-head and valve service, camshaft and cam-chain work, clutch, starter clutch, transmission and crankshaft inspection.

• FI diagnostics: User- and dealer-mode self-diagnosis, Suzuki Diagnosis System procedures, DTC fault isolation, ECM terminal information, fail-safe coverage, primary/secondary injector tests and TPS/STP adjustment.

• Fuel and exhaust work: Fuel-pressure and delivery testing, pump/filter service, throttle-body cleaning, injector inspection, fast-idle adjustment, synchronization, EXCVA/EXCV service, cable replacement and actuator adjustment.

• Chassis and brakes: Fork disassembly and reassembly, suspension setup, steering and swingarm service, wheel-bearing work, caliper/master-cylinder repair, hydraulic bleeding, tire balancing and drive-chain cutting/joining.

• Electrical and cooling systems: Charging, starter/interlock and ignition diagnosis, immobilizer checks, combination-meter and lighting tests, cooling-system pressure tests and water-pump repair.

• Parts and diagram reference: 64 numbered parts figures, OEM listings and a part-number index, plus regional wiring diagrams, FI-system wiring, lubrication charts, cooling circuits and routing views.

It is written for technicians and experienced mechanics who already have Suzuki motorcycle service knowledge, suitable measuring equipment, and the required special tools.

Internal Engine Inspection and Reassembly

The engine chapter separates components serviceable in the frame from those requiring engine removal. Step-by-step procedures extend to valve-guide replacement, valve-seat servicing and transmission-shaft disassembly and reassembly.

Piston, cylinder-bore, crankcase and connecting-rod inspection is supported by clearance limits and bearing-selection information. Journal and thrust-bearing sections distinguish the required measurements and replacement choices.

Exploded assembly views identify tightening points, lubricants and locking agents. A transmission cross-section shows gear, bushing, washer and snap-ring positions. The oil pump is inspected and replaced as an assembly rather than internally rebuilt.

Stored FI Data and Throttle-System Diagnosis

FI troubleshooting combines complaint analysis and visual checks with sensor-circuit tests, injector diagnosis, fuel-pump relay checks and EXCV actuator fault tracing. SDS procedures cover data capture, stored-fault information and diagnostic-history reset.

Comparing saved readings from normal operation with data captured during a fault supports diagnosis when the complaint is difficult to reproduce.

Turning the EXCVA pulley with a wrench can damage the actuator’s internal gears. Snapping the throttle valves from fully open to fully closed after disconnecting the cables can damage the valves and throttle body.

Cooling, Suspension and Brake Service

Cooling coverage includes radiator-cap testing, thermostat and ECT-sensor inspection, cooling-fan checks, and water-pump seal inspection and replacement. Engine-lubrication charts and cooling-circuit layouts show how the related passages and components connect.

Fork procedures cover seal replacement, oil-level setting and spring-preload and damping adjustment. Steering-tension checks and swingarm pivot-thrust adjustment provide the setup information needed after chassis work.

Rear shock procedures cover removal, inspection, replacement and suspension adjustment; the shock absorber is identified as internally unserviceable. Brake sections cover calipers and master cylinders, supported by front and rear brake-hose routing views.

Separate electrical sections provide charging-system fault charts, starter and side-stand/ignition-interlock checks, ignition tests, immobilizer information, combination-meter diagnosis, lighting tests and relay inspection.

Configuration-Specific Parts and Workshop References

Regional remarks and body-color codes distinguish configuration-specific parts. The catalog’s millimeter-to-inch chart and indexed part-number listing support identification across engine, transmission, electrical and body assemblies.

The special-tool directory identifies the SDS Set 09904-41010 and Mode Selection Switch 09930-82720. Chassis references include the drive-chain cutting and joining tool 09922-22711 and front-fork oil-seal installer 09940-52861.

Related sections provide torque tables, fluid capacities and approved-fluid specifications, electrical test values, adjustment data, clearances and wear limits.

Fuel-system, brake, engine, and suspension repair can involve fire, pressurized fluid, lifting, and road-safety hazards. Follow the factory warnings, use the specified tools, and obtain qualified help for work beyond your training or equipment.

Examples of Valve Clearances and Injector Test Data

For the K6 engine, the valve-clearance section specifies cold clearances of 0.08–0.18 mm for intake valves and 0.18–0.28 mm for exhaust valves. Shim-selection tables support adjustment.

The FI fault-isolation charts specify 11–13 Ω at 20 °C (68 °F) for both primary and secondary injectors, measured between the disconnected injector’s terminals.