2006–2007 Suzuki GSX-R600 Gixxer Service Manual (P/N 99500-35100-01E)

This Suzuki factory service manual covers the 2006–2007 GSX-R600 (K6/K7) Gixxer under publication P/N 99500-35100-01E. Its 12 sections cover inspection, diagnosis, disassembly, and repair, with market-specific service information.

• Engine and transmission: Engine removal, cylinder-head overhaul, crankshaft and piston inspection, gearbox disassembly, clutch replacement, and valve clearance adjustment.

• Fuel injection diagnosis: Suzuki Diagnosis System (SDS) procedures, injector circuit tests, fuel-pressure and delivery checks, throttle valve synchronization, and sensor adjustment.

• Exhaust and emissions: Exhaust Control Valve Actuator (EXCVA) inspection, exhaust-control cable replacement and adjustment, plus PAIR system inspection.

• Cooling and lubrication: Coolant replacement and bleeding, cooling-circuit pressure testing, thermostat checks, water-pump service, engine oil-pressure testing, and oil/filter replacement.

• Chassis and brakes: Inverted front-fork service, steering tension adjustment, suspension-bearing replacement, brake caliper and master-cylinder rebuilding, and brake bleeding.

• Electrical systems: Wiring diagrams, charging-system tests, starter-motor repair, ignition troubleshooting, lighting specifications, and regional immobilizer information.

Written for mechanics who already have the knowledge, skills, and special tools needed to service Suzuki motorcycles.

Internal Engine and Transmission Repair

Cylinder-head work includes valve-guide replacement and valve-seat servicing. Crankshaft journal and thrust-bearing selection tables accompany internal measurements, while camshaft timing and clutch-lifter adjustment receive their own procedures. Inspection limits and component-specific torque tables accompany the repair instructions.

Exploded views, tappet shim selection tables, and the Transmission Parts Location section view support component identification and assembly. Gearbox inspection includes shift-fork clearances, shaft bearings, and gear positioning.

The valve-seat instructions warn that lapping can remove the protective surface treatment from the titanium valves.

SDS Diagnosis, Fuel Delivery, and Regional Wiring

Fault tracing: Diagnostic Trouble Codes (DTCs), ECM connector pinouts, sensor thresholds, and saved SDS data help compare a reported fault with normal operating data when an intermittent symptom is difficult to reproduce.

The procedures identify mode select switch 09930-82720 and SDS set tool 09904-41010. Detailed SDS setup and trigger operation refer to a separate SDS operation manual.

Throttle-body service: Primary and secondary injectors have separate diagnostic sections. Synchronization and TP/STP sensor adjustments are covered; throttle-body disassembly leaves the Secondary Throttle Valve Actuator (STVA) and throttle valves installed.

Electrical references include the FI system wiring diagram, separate market wiring sheets, and wiring-harness routing drawings. Immobilizer coverage applies to E-02/E-19/E-24, while HO2 sensor inspection is specified for E-02/E-19.

Exhaust Control and Emissions Equipment

EXCVA instructions cover actuator positioning, cable identification, and adjustment checks. The manual warns that forcing its pulley with a wrench can damage the actuator's internal gears.

PAIR coverage includes reed-valve, hose, and solenoid checks. EVAP coverage is limited to E-33 California maintenance requirements; the label-location chart identifies the California vacuum-hose routing label.

Cooling Circuits and Engine Oil Flow

Radiator-cap testing and water-pump seal inspection supplement the cooling-system procedures. The engine lubrication system chart traces oil through the galleries, bearings, and piston-cooling jets.

Fork, Suspension, and Brake Service

Fork procedures cover seals, oil, springs, and cartridge removal. The cap-bolt assembly and inner-rod/damper-rod cartridge are kept intact during this work. The rear shock is treated as a non-serviceable unit, with inspection, replacement, adjustment, and disposal instructions.

Steering tension is checked with a spring scale. Swingarm and linkage-bearing procedures accompany brake-disc inspection and front/rear brake seal replacement.

For engine internals, brakes, and chassis work, use secure supports and seek help from a qualified technician when the procedure exceeds your experience.

Valve, Filter, Fuel-Pressure, and Chain Specification Examples

These are a few of the maintenance and fuel-system specifications included in the manual. Cold intake valve clearance is 0.08–0.18 mm, and the oil-filter tightening specification is 20 N·m.

The fuel-pressure test specifies approximately 300 kPa (43 psi) with the ignition switched on. Drive-chain adjustment calls for 20–30 mm of slack with the motorcycle on its side stand.

PDF Navigation and Included Pages

Text search and diagram detail: The service text is searchable, with embedded bookmarks for the chapters and major subsections. Small wire-color codes and connector labels in the wiring diagrams require zooming for comfortable reading.

Supplied as one printable 517-page PDF in English. The total includes the front and back covers, six introductory pages, and the publication page.