Suzuki 2007 gsxr 600 Service Manual

GSX-R750
99500-37130-01E

Suzuki 2007 gsxr 600 Specifications

General

Engine Type	599cc, 4-stroke, liquid-cooled, DOHC
Bore x Stroke	67.0mm x 42.5mm
Compression Ratio	12.5:1
Fuel System	Fuel injection
Ignition	Electronic ignition (Transistorized)
Lubrication	Wet sump
Starter	Electric
Transmission	6-speed constant mesh
Final Drive	Chain
Front Suspension	Inverted telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Front Brakes	Dual hydraulic disc
Rear Brakes	Single hydraulic disc
Front Tire Size	120/70ZR17M/C (58W)
Rear Tire Size	180/55ZR17M/C (73W)
Overall Length	2040 mm (80.3 in)
Overall Width	715 mm (28.1 in)
Wheelbase	1400 mm (55.1 in)
Ground Clearance	130 mm (5.1 in)
Seat Height	810 mm (31.9 in)
Fuel Capacity	17.0 L (4.5 US gal)
Overall Height	1135 mm (44.7 in)

Summary

FOREWORD

GENERAL INFORMATION

Provides essential details about the motorcycle, recommendations, and specifications.

WARNING/CAUTION/NOTE

Explains signal words and general safety precautions for service.

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

Lists recommended fluids for optimal performance and protection.

SPECIFICATIONS

Provides detailed technical specifications for the motorcycle.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Lists recommended service intervals for various maintenance tasks.

LUBRICATION POINTS

Indicates major lubrication points on the motorcycle.

AIR CLEANER

Instructions for inspecting and replacing the air cleaner element.

SPARK PLUG

Details spark plug inspection, removal, and installation procedures.

VALVE CLEARANCE

Procedures for checking and adjusting valve clearance.

ENGINE OIL AND OIL FILTER

Instructions for replacing engine oil and oil filter.

CLUTCH

Procedures for inspecting and adjusting clutch cable play.

COOLING SYSTEM

Details on checking and changing engine coolant.

DRIVE CHAIN

Instructions for checking, adjusting, cleaning, and lubricating the drive chain.

BRAKE

Information on brake fluid level check and inspection.

BRAKE PADS

Procedures for checking and replacing front and rear brake pads.

STEERING

Procedures for inspecting and adjusting steering tension.

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

Lists components that can be removed without taking the engine out of the frame.

ENGINE REMOVAL AND INSTALLATION

Step-by-step guide for removing and installing the engine.

ENGINE DISASSEMBLY

Procedures for disassembling the engine.

CYLINDER HEAD

Procedures for removing and inspecting the cylinder head.

CAMSHAFT

Details on camshaft identification, wear, and journal inspection.

CLUTCH

Information on clutch inspection and removal.

WATER PUMP

Procedures for removing, inspecting, and installing the water pump.

CRANKSHAFT

Procedures for removing the crankshaft.

PISTON AND CONROD

Procedures for removing piston and conrod.

ENGINE REASSEMBLY

Steps for reassembling the engine.

FI SYSTEM DIAGNOSIS

PRECAUTIONS IN SERVICING

General safety precautions for servicing the FI system.

ELECTRICAL CIRCUIT INSPECTION PROCEDURE

General methods for inspecting electrical circuits.

USING THE MULTI-CIRCUIT TESTER

Instructions and precautions for using the multi-circuit tester.

FI SYSTEM TECHNICAL FEATURES

Overview of the fuel injection system's technical features.

FI SYSTEM PARTS LOCATION

Identifies the locations of FI system components on the motorcycle.

FI SYSTEM WIRING DIAGRAM

Visual representation of the FI system's electrical connections.

SELF-DIAGNOSIS FUNCTION

Explains the motorcycle's self-diagnosis capabilities.

MALFUNCTION CODE AND DEFECTIVE CONDITION

Lists malfunction codes and their corresponding detected conditions and checks.

TPS ADJUSTMENT

Procedure for adjusting the Throttle Position Sensor.

FI SYSTEM TROUBLESHOOTING

Guide for troubleshooting FI system issues.

FUEL SYSTEM AND THROTTLE BODY

FUEL DELIVERY SYSTEM

Overview of the fuel delivery system components and operation.

FUEL SYSTEM

General information about the fuel system.

FUEL PUMP AND FUEL FILTER REMOVAL

Procedures for removing the fuel pump and fuel filter.

THROTTLE BODY

Information about the throttle body construction.

AIR CLEANER BOX REMOVAL AND INSTALLATION

Procedures for removing and installing the air cleaner box.

THROTTLE BODY REMOVAL

Step-by-step guide for removing the throttle body assembly.

THROTTLE BODY DISASSEMBLY

Procedures for disassembling the throttle body.

THROTTLE BODY CLEANING

Instructions for cleaning the throttle body.

THROTTLE BODY REASSEMBLY

Procedures for reassembling the throttle body.

STP SENSOR ADJUSTMENT

Step-by-step guide for adjusting the STP sensor.

THROTTLE VALVE SYNCHRONIZATION

Procedures for synchronizing throttle valves.

EXHAUST SYSTEM

EXHAUST CONTROL SYSTEM

Overview of the exhaust control system components and function.

EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)

Details on the EXCVA and EXCV components.

EXCVA REMOVAL

Procedures for removing the EXCVA.

EXCV CABLE REPLACEMENT

Procedures for replacing EXCV cables.

EXCVA ADJUSTMENT

Step-by-step guide for adjusting the EXCVA.

EXCV/EXHAUST PIPE, MUFFLER REMOVAL

Procedures for removing the EXCV, exhaust pipe, and muffler.

COOLING AND LUBRICATION SYSTEM

ENGINE COOLANT

Information on engine coolant, its mixture, and handling precautions.

COOLING CIRCUIT INSPECTION

Steps to inspect the cooling circuit for tightness.

RADIATOR REMOVAL

Steps to remove the radiator assembly.

WATER HOSE INSPECTION

Inspection of water hoses for damage or leakage.

COOLING FAN

Procedures for cooling fan removal and inspection.

ECT SENSOR

Procedures for ECT sensor removal, installation, and inspection.

THERMOSTAT

Procedures for thermostat removal, inspection, and installation.

WATER PUMP

Procedures for water pump removal, disassembly, inspection, and reassembly.

LUBRICATION SYSTEM

Information on the lubrication system.

CHASSIS

FASTENER REMOVAL AND INSTALLATION

Procedures for removing and installing Type A and Type B fasteners.

BODY COWLING COVER AND LOWER BRACKET COVER

Procedures for removing and installing body and lower bracket covers.

FRONT WHEEL

Information on front wheel construction.

FRONT FORK

Information on front fork construction.

STEERING

Information on steering construction.

HANDLEBARS

Information on handlebar construction.

REAR WHEEL

Information on rear wheel construction.

REAR SHOCK ABSORBER

Information on rear shock absorber construction.

FRONT BRAKE

Information on front brake construction.

BRAKE DISC INSPECTION

Inspecting front brake discs for damage and runout.

MASTER CYLINDER REMOVAL AND DISASSEMBLY

Procedures for removing and disassembling the master cylinder.

REAR BRAKE

Information on rear brake construction.

BRAKE PAD REPLACEMENT

Procedures for replacing rear brake pads.

BRAKE FLUID REPLACEMENT

Procedures for replacing brake fluid and bleeding the system.

CALIPER REMOVAL AND DISASSEMBLY

Procedures for removing and disassembling the rear brake caliper.

TIRE AND WHEEL

Information on tire and wheel removal and inspection.

DRIVE CHAIN

Information on drive chain maintenance.

ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

General safety precautions for electrical system servicing.

USING THE MULTI-CIRCUIT TESTER

Instructions and precautions for using the multi-circuit tester.

LOCATION OF ELECTRICAL COMPONENTS

Identifies the locations of various electrical components.

CHARGING SYSTEM

Troubleshooting and inspection of the charging system.

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM

Troubleshooting and inspection of the starter and interlock systems.

IGNITION SYSTEM

Overview of the ignition system.

IMMOBILIZER (Except for E-03, 28, 33)

Description and operation of the immobilizer system.

TROUBLESHOOTING

Troubleshooting guide for ignition system issues (no spark/poor spark).

COMBINATION METER

Description of the combination meter components.

ENGINE COOLANT TEMPERATURE METER AND INDICATOR

Information on the engine coolant temperature gauge.

LAMPS

Information on headlight, brake, license plate, and turn signal lights.

RELAYS

Information on various relays.

IGNITION SWITCH REMOVAL

Procedures for removing the ignition switch.

SWITCHES INSPECTION

Inspection procedures for various switches.

BATTERY

Information about the MF battery specifications and initial charging.

SERVICING INFORMATION

TROUBLESHOOTING

Guide for troubleshooting FI system malfunctions.

ENGINE

Troubleshooting common engine complaints.

RADIATOR (COOLING SYSTEM)

Troubleshooting common cooling system issues.

CHASSIS

Troubleshooting common chassis-related issues.

BRAKES

Troubleshooting common brake issues.

ELECTRICAL

Troubleshooting common electrical system issues.

BATTERY

Troubleshooting common battery complaints.

WIRING HARNESS, CABLE AND HOSE ROUTING

Information on routing various wires, cables, and hoses.

SPECIAL TOOLS

List of special tools required for servicing.

TIGHTENING TORQUE

Torque specifications for engine components.

SERVICE DATA

Essential service data and specifications.

EMISSION CONTROL INFORMATION

EMISSION CONTROL SYSTEMS

Overview of the emission control systems.

FUEL INJECTION SYSTEM

Information about the fuel injection system.

CRANKCASE EMISSION CONTROL SYSTEM

Explanation of the crankcase emission control system.

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)

Overview of the PAIR and exhaust control systems.

PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION

Inspection procedures for PAIR system components.

HO2 SENSOR INSPECTION (For E-02, 19)

Inspection procedures for the HO2 sensor.

WIRING DIAGRAM