GSR600 ABS Service Manual

9 9 5 0 1 - 3 6 1 5 0 - 0 1 E

USE THIS MANUAL WITH:GSR600 SERVICE MANUAL (99500-36161-01E)

GSR600A

GSR600AK7 (’07-MODEL) 1

GSR600AK7 (’07-MODEL)

This manual describes service data, service specifications and ABS servicing procedureswhich 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 .............................................................................................. 3INTRODUCTION OF ABS .................................................................................. 5

FRONT AND REAR WHEEL SPEED SENSORS..................................... 5ABS CONTROL UNIT ............................................................................... 5ABS CONTROL UNIT CALCULATING PROCESS.................................. 6HYDRAULIC UNIT (HU)............................................................................ 7FAIL-SAFE FUNCTION............................................................................. 8SELF-DIAGNOSIS FUNCTION AND ABS INDICATOR LIGHT............... 8

CAUTIONS IN SERVICING ................................................................................ 9ABS WIRING............................................................................................. 9FUSES....................................................................................................... 9BATTERY.................................................................................................. 9ABS CONTROL UNIT/HU......................................................................... 10ABS INFORMATION................................................................................. 10TESTER..................................................................................................... 11

ABS COMPONENTS.......................................................................................... 12ABS COMPONENTS LOCATION............................................................. 12ABS COUPLER CONNECTION DIAGRAM ............................................. 13ABS WIRING DIAGRAM........................................................................... 14ABS CONTROL UNIT SYSTEM DIAGRAM ............................................. 15

ABS TROUBLESHOOTING ............................................................................... 16ABS TROUBLESHOOTING DESCRIPTION ............................................ 16TROUBLESHOOTING PROCEDURE ...................................................... 17BASIC TROUBLESHOOTING DIAGRAM................................................ 18INFORMATION GATHERING................................................................... 19PRE-DIAGNOSIS INSPECTION ............................................................... 20ABS INDICATOR LIGHT INSPECTION.................................................... 23DTC (Diagnostic Trouble Code) OUTPUT.............................................. 27DTC DELETING AND ABS OPERATION CHECK................................... 29SDS CHECK.............................................................................................. 31

SAMPLE

COPYRIGHT SUZUKI MOTOR CORPORATION 2007

2 GSR600AK7 (’07-MODEL)

GSR600AK7 (’07-MODEL)

CONTENTS

CT

USE OF SDS DIAGNOSTIC PROCEDURES........................................... 32USE OF SDS DIAGNOSIS RESET PROCEDURE .................................. 33ACTIVE CONTROL INSPECTION ........................................................... 35DTC TROUBLESHOOTING ..................................................................... 40ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION........................................................................................ 62COMBINATION METER........................................................................... 70

WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION ............. 71WIRE HARNESS ROUTING..................................................................... 71FRONT BRAKE HOSE ROUTING ........................................................... 73REAR BRAKE HOSE ROUTING.............................................................. 74FRONT WHEEL SPEED SENSOR INSTALLATION ............................... 75REAR FENDER HEAT SHIELD INSTALLATION.................................... 77

SPECIAL TOOLS............................................................................................... 78TIGHTENING TORQUE ..................................................................................... 78SERVICE DATA................................................................................................. 79WIRING DIAGRAM ............................................................................................. 89E
OUNTRY AND AREA CODES
he following codes stand for the applicable country(-ies) and area(-s).

MODEL CODE COUNTRY or AREA EFECTIVE FRAME NO.

GSR600AE-02E-19E-24

U.K.EU

Australia

JS1B9112100 100001 –JS1B9112100 100001 –JS1B9112300 100001 –

GSR600AUE E-19 EU JS1B9212100 100001 –

SAMPL


SPECIFICATIONSDIMENSIONS AND DRY MASSOverall length .......................................................................... 2 090 mmOverall width ........................................................................... 795 mm

Overall height .......................................................................... 1 075 mmWheelbase .............................................................................. 1 440 mmGround clearance.................................................................... 130 mmSeat height .............................................................................. 785 mmDry mass ................................................................................. * 188 kg

ENGINEType ........................................................................................ Four stroke, liquid-cooled, DOHCNumber of cylinders ................................................................ 4Bore......................................................................................... 67.0 mmStroke...................................................................................... 42.5 mmDisplacement .......................................................................... 599 cm3

Compression ratio ................................................................... 12.5 : 1Fuel system............................................................................. Fuel injectionAir cleaner ............................................................................... Paper elementStarter system ......................................................................... ElectricLubrication system .................................................................. Wet sumpIdle speed................................................................................ 1 300 ± 100 r/min

DRIVE TRAINClutch ...................................................................................... Wet multi-plate typeTransmission........................................................................... 6-speed constant meshGearshift pattern ..................................................................... 1-down, 5-upPrimary 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

SAMPLE


CHASSISFront suspension .................................................................... Telescopic, coil spring, oil dampedRear suspension ..................................................................... Link type, coil spring, oil dampedFront fork stroke...................................................................... 130 mmRear wheel travel .................................................................... 134 mmCaster ..................................................................................... 25° 15’Trail ......................................................................................... 104 mmSteering angle......................................................................... 33° (right & left)Turning radius ......................................................................... 2.9 mFront brake.............................................................................. Disc brake, twinRear brake .............................................................................. Disc brakeFront tire size .......................................................................... 120/70ZR17M/C (58W), tubelessRear tire size........................................................................... 180/55ZR17M/C (73W), tubeless

ELECTRICALIgnition type............................................................................. Electronic ignition (Transistorized)Ignition timing.......................................................................... 6° B.T.D.C. at 1 300 r/minSpark plug............................................................................... NGK CR9E or DENSO U27ESR-NBattery..................................................................................... 12 V 28.8 kC (8 Ah)/10 HRGenerator................................................................................ Three-phase A.C. generatorMain fuse ................................................................................ 30 AFuse........................................................................................ 10/10/15/10/10/15/15/20 AHeadlight................................................................................. 12 V 60/55 W H4Turn signal light....................................................................... 12 V 10 WBrake light/Taillight.................................................................. LEDPosition light............................................................................ 12 V 5 W × 2Licence plate light ................................................................... 12 V 5 WSpeedometer light................................................................... LEDTachometer light ..................................................................... LEDNeutral indicator light .............................................................. LEDHigh beam indicator light ........................................................ LEDTurn signal indicator light ........................................................ LEDOil pressure/Engine coolant temperature indicator light ......... LEDFuel injection indicator light..................................................... LEDImmobilizer indicator light ....................................................... LEDABS indicator light................................................................... * LED

CAPACITIESFuel tank ................................................................................. 16.5 LEngine oil, oil change ............................................................ 3 200 ml

with filter change.................................................. 3 600 mloverhaul............................................................... 3 900 ml

Coolant.................................................................................... 2.8 L

These specifications are subject to change without notice.

SAMPLE


INTRODUCTION OF ABSFRONT AND REAR WHEEL SPEED SENSORSWheel speed sensor consists of wheel speed sensor 1 andsensor rotor 2.

ABS CONTROL UNITABS control unit calculates signals input from each one of frontand rear wheel speed sensors, monitors the slipping conditionsof the wheels and, at the same time, sends control signal toHydraulic Unit (HU).This ABS control unit/HU can not be disassembled.

ABS control unit

HU

ABS contorl unit/HUABS contorl unit

MainCPU

ABS indicator light

MotorM

Front IN/V

Rear OUT/VRear IN/VFront OUT/V

Ignition

Battery

Front wheelspeed sensor

Rear wheelspeed sensor

Brake light switch

Mode selection switch

Input interface

Wheelspeed sensor circuit

SW input circuit

SDS Communicationcircuit

Powerunit

Output interface

Indicator light circuit

Solenoid valve circuit

Motor circuit

Reciprocal checking

Watch IC

OUT/V: Outlet solenoid valveIN/V: Inlet solenoid valve

SAMPLE


ABS CONTROL UNIT CALCULATING PROCESSThe ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occurduring the ABS control unit calculating process. ABS control is performed in one cycle every 10/1 000 sec-onds. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlledby the ABS and a diagnostic trouble code is stored.

Normal calculating process Calculating process when a malfunction occurs

Ignition switch turned to ON

ABS control unit Initialization

Self-diagnosis(during start up)

Self-diagnosis (while riding)

Wheel speed sensor signalenters

ABS control calculation

Hydraulic unit control signaloutput

1 cycle10/1 000 seconds

ABS indicator lightlights up

Is ABS under control ?

Diagnostic trouble codememorized

Malfunctionindicated

Malfunctionindicated

No malfunction

Correct

Interim ABS control

YES

NO

Prohibition of ABS control

SAMPLE


HYDRAULIC UNIT (HU)The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS controlunit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rearbrake systems individually by operating separate components for the front and the rear, except for the pumpdrive motor, which is shared by both systems.

Rear brake light switch

Rear wheel speed sensor

Front wheel speed sensor

Rear system Front system

ABS indicator light

Front brake light switch

One-wayvalve

One-wayvalve

Damper

Reservoir Reservoir

Solenoidvalve OUT

Solenoidvalve OUT

Solenoidvalve IN

Solenoidvalve IN

Motor

Rear brake caliper

Front brake caliper

Front brake lever/master cylinder

ABS control unit

HU

M

Rear brake pedal/master cylinder

SAMPLE


FAIL-SAFE FUNCTIONIf malfunction occurs in the ABS electric system, this sets fail-safe relay OFF. Consequently, motor relay willbe set OFF and the indicator light ON, and no current will be applied to motor solenoid valve inactivatingABS and turning ABS indicator light ON. In this case, it functions as the normal brake. However, if malfunc-tions occurs while ABS is being activated, when ABS control unit diagnoses that the operation can continue,it will effectuate ABS provisional control (turning the ABS indicator light ON). Upon the moment when ABSprovisional control is over, the fail-safe relay will be set OFF.

SELF-DIAGNOSIS FUNCTION AND ABS INDICATOR LIGHT The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions asdiagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of themalfunction. The special tool, when connected to the mode select coupler, enables the ABS indicator light todisplay the diagnostic trouble codes.

ABS INDICATOR LIGHT The ABS indicator light informs the rider of any ABS malfunc-tions. If a malfunction occurred, the ABS indicator light flashes,during the self-diagnosis, to indicate the diagnostic trouble codeso that the correct part can be repaired.

• When the ignition switch is turned to ON, the ABS indicatorlight lights up even if no malfunction has occurred, to indicatethat the bulb is not burnt out. It will go off after the motorcycleis ridden at more than 10 km/h.

• If an ABS malfunction has occurred, the ABS indicator lightkeeps lighting up.

• When a malfunction has occurred in the ABS, connect thespecial tool to the mode select coupler to display the diagnos-tic trouble code on the ABS indicator light. (Page 27)

09930-82710: Mode select switch

ABS control unit

CPU

Ignition switch

ABS indicator light

Motor relayM

Motor

Fail-safe relay

Indicator relayIndicator relay

Solenoid valvesSolenoid valves

O

B/W

SAMPLE


CAUTIONS IN SERVICINGABS WIRING• The ABS parts are connected to various lead wires. The cou-

pler and lead wire connections, as well as the lead wire andwire harness routings must be done correctly. Make sure thatthe proper clamps are used and positioned correctly.

NOTE:If all of the connections are not properly connected, the ABSmay not operate correctly. For connector and coupler precau-tions. (GSR600K6 9-3)

FUSES• If a fuse is blown, find the cause of the problem and correct it

before replacing the fuse.• Only use a fuse of the specified rating.• Never improvise when replacing a fuse.

BATTERY• Only use a fully charged battery.• In order to prevent damage to the ABS control unit etc., be

sure to connect the battery properly.• Never disconnect the battery or any other lead wires while the

engine is running.

NOTE:For battery and battery connection precautions. (GSR600K6 9-4)

Click

Click

SAMPLE


ABS CONTROL UNIT/HU• Never allow dust or water to contact the ABS control unit/HU.

• Never subject the ABS control unit/HU to strong impacts orallow them to be dropped.

• The ABS control unit/HU cannot be disassembled. Replacethe whole unit with a new one.

ABS INFORMATION

• Be sure to route the brake hoses correctly.• The ABS does not shorten the motorcycle’s braking distance.

When riding down slopes or on wet or bumpy roads the brak-ing distance is lengthened as compared to a motorcycle with-out ABS. In addition, braking distance increases more, whenthe road is slippery.

• The ABS does not control slides which may occur when brak-ing while turning. As with a motorcycle that does not haveABS, it is best not apply the brakes while turning.

• The brake levers may move by themselves when they areapplied. This is not a malfunction.

• Only use the specified tires.

Incorrect

Incorrect

Incorrect

* Be sure to bleed air from the brake fluid circuit whenthe brake is felt spongy or when a brake relating partis replaced.

* Never ride the motorcycle before bleeding the air.

SAMPLE


TESTER• Use the Suzuki multi-circuit tester (09900-25008).• Use well-charged batteries in the tester.• Be sure to set the tester to the correct testing range.• Since the resistance may differ depending on the tester used

and the temperature, the resistance should be set to the spec-ification.

USING THE TESTER• Incorrectly connecting the + and - probes may cause the

inside of the tester to burnout.• If the voltage and current are not known, make measure-

ments using the highest range.• When measuring the resistance with the multi-circuit tester, ∞

will be shown as 10.00 MΩ and “1” flashes in the display.• Check that no voltage is applied before making the measure-

ment. If voltage is applied the tester may be damaged.• After using the tester, turn the power off.

09900-25008: Multi-circuit tester set

NOTE:* When connecting the multi-circuit tester, use a needle pointed

probe set to the back side of the lead wire coupler and connectthe probes of tester to them.

* Use a needle pointed probe set to prevent the rubber of thewater proof coupler from damage.

09900-25009: Needle pointed probe set

MULTI-CIRCUIT TESTER

NEEDLE POINTED PROBE SET

SAMPLE


ABS COMPONENTSABS COMPONENTS LOCATION

1 ABS indicator light 4 ABS control unit/HU2 Front wheel speed sensor rotor 5 Rear wheel speed sensor rotor3 Front wheel speed sensor 6 Rear wheel speed sensor

SAMPLE


ABS COUPLER CONNECTION DIAGRAMRefer to GSR600 service manual section “WIRE COLOR”.

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

(Har

nes

s si

de)

O/R

B/Bl

B/R O/B

O/W

Y/G

Y/W

W/B

O/G

W/B Y/G

Y/W

O/W

O/B

WB

B/RW/R

O

R Br

Gr

R

O

Br

O/G

W/R

Gr

O/G B/W

O

B/W

B/Y

Gr

W/Y

B/R

O/Y

Br

W/R

O

B/W

R/Bl

B/W

R/B

O/G

W/B

W/B

O

B/W

Gr

R/Bl

O/Y

R/B

B/W

Gr O/Y

R/BR/Bl

B/R

Lg

O/G

B/Lg

Bl/B

B/G

O/G

Lg

O

B/G

Bl/B

R/B

Br

Y

Br

B/W

B/W

B B

Y B/Br

Br

WB

B/YW/Y

O

AB

S C

ON

TR

OL

UN

ITM

OD

E S

ELE

CT

CO

UP

LER

SD

S C

OU

PL

ER

IGN

ITIO

N S

WIT

CH

FRO

NT

WH

EE

L S

PE

ED

SE

NS

OR

HA

ND

LEB

AR

SW

ITC

H (F

RO

NT

BR

AK

E S

WIT

CH

)

RE

AR

WH

EE

L S

PE

ED

SE

NS

OR

SP

EE

DO

ME

TE

R A

SP

EE

DO

ME

TE

R B

CO

NN

EC

TOR

RE

AR

BR

AK

E S

WIT

CH

FU

SE

BO

X

20A

SPA

RE

15A

AB

S-V

20A

AB

S-M

SPA

RE

10A

10AHEAD-HI

SPA

RE

10A

10AHEAD-LO

15AIGNITION

10ASIGNAL

10AFUEL

10AFAN

SAMPLE


ABS WIRING DIAGRAMRefer to GSR600 service manual section “WIRE COLOR”.

OB/WB/W

B/R B/RW/R W/R

B/Y B/YW/Y W/Y

OW/B

B/Y B/YW/R W/RW/B W/BR/Bl R/BlR/B R/BGr GrBr Br

B/R B/RO

O/Y O/YW/Y W/YB/WB/WB/WB/W

B/YW/RW/BR/BlR/BGrBr

B/RO

O/YW/YB/WB/W

R/Bl R/BlGr Gr

B/WB/WR/B R/BO/Y O/Y

R/BlGr

B/WR/BO/Y

R/Bl R/BlGr Gr

B/WB/WR/B R/BO/Y O/Y

R/BlGr

B/WR/BO/Y

B/WB/WB/W

R/WR/WR/W

B/WB/WB/W

RR

RRRR

RR

RR/B R/BR/WR/WR/Bl R/Bl

RR/BR/WR/Bl

OB/W

B/RW/R

B/YW/Y

BWBW

BWBW

B/W

W/B

B/W

W/B

GrB/W

RO

RO

B/G

O/GW/B

OO/Y

O/GW/B

BrBr

O/GO/G

B/RB/Bl

FU

SE

BO

X1.

HE

AD

HI

2. H

EA

D L

O3.

IGN

ITIO

N

4. S

IGN

AL

5. F

UE

L6.

FA

N

10A

10A

15A

10A

10A

15A

12

34

56

OF

FO

N

FRON

T BR

AKE

LIGH

T SW

ITCH

IGN

ITIO

N S

WIT

CH

ON

OF

F

REAR

BRA

KELI

GHT

SWIT

CHO

NO

FF

LOCK P

RE

AR

CO

MB

INA

TIO

N L

IGH

T

BA

TT

ER

Y

RW

SF

WS

FU

SE

BO

X

1: M

AIN

(30

A)

STA

RT

ER

M

OTO

RS

TAR

TE

R

RE

LA

Y

1

7: A

BS

MO

TOR

(20

A)

8: A

BS

VA

LVE

(1

5A)

78

AB

S C

ON

TR

OL

UN

IT

SPEE

DOM

ETER

ABS

MO

DE

SE

LE

CT

CO

UP

LE

R

SD

SC

OU

PL

ER

SAMPLE


ABS CONTROL UNIT SYSTEM DIAGRAMRefer to GSR600 service manual section “WIRE COLOR”.

Bat

tery

Igni

tion

Igni

tion

AB

S

Bra

ke li

ght

switc

h

Bra

ke li

ght s

witc

hA

BS

indi

cato

r lig

ht

Sol

enoi

dB

atte

ry

Fail

safe

rela

y

Mot

orre

lay

Gro

und

Fron

tw

heel

spee

dse

nsor

Rea

rw

heel

spee

dse

nsor

Mod

ese

lect

coup

ler

AB

S c

ontr

ol u

nit

M

Gro

und

2425

2 23 3

12 12

13 13

18 18

10 10

4 411 21

16 16

89

23

4

1012

1316

1821

2489 25

R

ear

brak

e so

leno

id O

UT

Fa

il sa

fe

B

Rea

r br

ake

sole

noid

IN

Mot

or r

elay

B

Fr

ont b

rake

sol

enoi

d O

UT

M

otor

B

Fr

ont b

rake

sol

enoi

d IN

Mot

orgr

ound

SD

S

O/Y

Br

W/B

R/B

lR

/B

B/W

B/W

W/Y

B/Y

B/R

OG

r

W/R

SAMPLE


ABS TROUBLESHOOTINGABS TROUBLESHOOTING DESCRIPTIONMany of the ABS malfunction diagnosing operations are performed by checking the wiring continuity. Quickand accurate detection of malfunctions within the complex circuitry assures the proper operation of the ABS.Before beginning any repairs, thoroughly read and understand this Supplementary Service Manual.The ABS is equipped with a self-diagnosis function. The detected malfunction is stored as a diagnostic trou-ble code which causes the ABS indicator light to light up or flash in set patterns to indicate the malfunction.Diagnostic trouble codes are stored even when the ignition switch is turned to OFF and they can only beerased manually. In order to repair the ABS correctly, ask the customer for the exact circumstances underwhich the malfunction occurred, then check the ABS indicator light and the output diagnostic trouble codes.Explain to the customer that depending on how the motorcycle is operated (e.g., if the front wheel is off theground), the ABS indicator light may light up even though the ABS is operating correctly.

ABS OPERATION AND ABS INDICATOR LIGHTThe ABS indicator light shows the ABS operating condition. Dur-ing normal operation, the ABS indicator light lights up when theignition switch is turned to ON and goes off after the motorcycleis ridden at more than 10 km/h. If a malfunction has occurred,the ABS indicator light keeps lighting up.

STORED DTCs (Diagnostic Trouble Codes)As for the diagnostic trouble code, the code of the first malfunction occurred during one ignition ON periodwill be stored. Pay attention to the fact that even though there may occur several malfunctions in one ON-period, only one code will be stored. Codes of malfunction that occurred in the past are all stored, but thesame diagnostic trouble code will not be redundant. Check and see if any diagnostic trouble code remains, by actually running the machine to activate ABS andby carrying out the self-diagnosis after deleting the diagnostic trouble code once the malfunctioned part isrepaired.

The ABS indicator light goes off when the motorcy-cle is ridden at more than 10 km/h.

The ABS is normally activated.

The ABS indicator light keeps lighting up eventhough the motorcycle is ridden at more than 10 km/h.

One or more malfunction has been found and ABS activation been hanged up.

The ABS indicator light does not light up when turn-ing the ignition switch ON.

Check the wire harness and combination meter. (Page 23)

SAMPLE


TROUBLESHOOTING PROCEDURETroubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, anerror in diagnosis may result.

1. Gather information from the customer. (Page 19)2. Perform the pre-diagnosis inspection. (Page 20)3. Inspect the ABS indicator light. (Page 23)4. Output the DTCs stored in the ABS control unit. (Page 27)5. Perform appropriate troubleshooting procedures according to the DTCs output. (Page 28)

If troubleshooting procedures cannot be performed, try to determine the cause of the malfunction accordingto the information gathered in 1 through 4 and inspect the wiring. (Page 14 and 15)

6. Inspect the ABS components. (Page 67)7. Delete the DTCs and check the brake operation. (Page 29)

* When disconnecting couplers and turning the ignition switch ON, disconnect the ABS controlunit coupler in order to prevent a DTC from being stored.

* Each time a resistance is measured, the ignition switch should be set to OFF.

SAMPLE


BASIC TROUBLESHOOTING DIAGRAM

1. Gather information from the customer. (!Page 19)

2. Perform the pre-diagnosis inspection. (!Page 20)

6. Inspect the ABS components. (!Page 67)

4. Output the DTCs stored in the ABS control unit. (!Page 27)

7. Delete the DTCs and check the brake operation. (!Page 29)

5. Perform appropriate troubleshooting procedures according to the DTCs output. (!Page 28)If troubleshooting procedures cannot be performed, try to determine the cause of the mal-function according to the information gathered in 1 through 4 and inspect the wiring. (!Page 14 and 15)

3. Inspect the ABS indicator light. (!Page 23)

SAMPLE


INFORMATION GATHERINGTo properly diagnose a malfunction, one must not make guesses or assumptions about the circumstancesthat caused it. Proper diagnosis and repair require duplicating the situation in which the malfunctionoccurred. If a diagnosis is made without duplicating the malfunction, even an experienced service technicianmay make a misdiagnosis and not perform the servicing procedure correctly, resulting in the malfunction notbeing repaired. For example, a malfunction that occurs only while braking on slippery surfaces will not occurif the motorcycle is ridden on a non-slippery surface. Therefore, in order to properly diagnose and repair themotorcycle, the customer must be questioned about the conditions at the time that the malfunction occurredmaking “Information gathering” very important. In order that the information obtained from the customer tobe used as a reference during troubleshooting, it is necessary to ask certain important questions concerningthe malfunction. Therefore, a questionnaire has been created to improve the information-gathering proce-dure.

Questionnaire Example

NOTE:The above form is a standard sample. It should be modified according to characteristic of each market.

Customer’s name License plate No. Frame serial No. Mileage

First registered year Date malfunction occurred Frequency of occurrence Weather of date of occur-rence

PROBLEM SYMPTOMSABS operation Past malfunctions and repairs

ABS does not work

ABS works so often with

Too long stopping distance

Others

CONDITIONS WHEN MALFUNCTION OCCUREDABS indicator light Riding conditions

Does not light up While stopping

Lights up Goes off after running over 10 km/h Yes No

Over 10 km/h

When turning Others

Flashes Brake operating conditions

Tires Usual braking

Abnormal air pressure Quick/hard braking

Less thread depth Interface

No specified tires installed Too big pulsations at brake leversRoad surface Too large brake lever strokesPaved road Others

Dry Wet Others Others

Unpaved road Abnormal noise from the ABS control unit/HU

Gravel Muddy Uneven Skid noise from the calipers

Others Vibration at the brake leversNote:

SAMPLE


PRE-DIAGNOSIS INSPECTIONThe mechanical and hydraulic components of the brake system should be inspected prior to performing anyelectrical checks. These inspections may find problems that the ABS could not detect; thus, shorteningrepair time.

BRAKEBrake fluid level check (GSR600K6 2-22)Brake pad inspection (GSR600K6 2-23)Brake fluid circuit air bleeding (GSR600K6 2-24)

Tire typeBRIDGESTONE (Front: BT014F Rear: BT014R)

Tire pressure (GSR600K6 2-26)Wheel (GSR600K6 8-8)

BATTERYBattery voltage• Turn the ignition switch OFF.• Remove the seat. (GSR600K6 8-3)• Measure the voltage between the + and - battery terminals

using the multi-circuit tester.

Battery voltage: 12.0 V and more


Tester knob indication: Voltage ()

If the voltage is less than 12.0 V, charge or replace the batteryand inspect the charging system. (GSR600K6 9-9)

* The standard tire fitted on this motorcycle is 120/70ZR17M/C (58W) for front and 180/55ZR17M/C (73W)for rear. The use of tires other than those specifiedmay cause instability. It is highly recommended touse a SUZUKI Genuine Tire.

* Replace the tire as a set, otherwise the DTC “25”(C1625) may be stored.

SAMPLE


ABS COMPONENTWheel speed sensor – sensor rotor clearance• Inspect the clearance between the wheel speed sensor and

sensor rotor for each wheel using the thickness gauge.

Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm

09900-20803: Thickness gauge09900-20806: Thickness gauge

ABS control unit/HU ground wire inspection• Turn the ignition switch OFF.• Remove the seat. (GSR600K6 8-3)• Disconnect the battery - lead wire.• Remove the frame covers. (GSR600K6 8-4)• Lift and support the fuel tank. (GSR600K6 5-3)

• Disconnect the ABS control unit coupler 1.SAMPLE


• Check for continuity between N (B/W) at the coupler and thebattery - terminal, also O (B/W) at the coupler and the bat-tery - terminal.


Tester knob indication: Continuity ()

If there are no continuity, repair the coupler or wire harness.

ABS control unit coupler (Harness end)

Battery terminal

SAMPLE


ABS INDICATOR LIGHT INSPECTIONStep 11) Check if the ABS indicator light lights up when turning the

ignition switch ON.

Does the ABS indicator light up?

The ABS indicator light lights upStep 21) Ride the motorcycle at more than 10 km/h.

Does the ABS indicator light go off?

The ABS indicator light does not light upStep 31) Remove the seat. (GSR600K6 8-3)2) Remove the right frame cover. (GSR600K6 8-4)

3) Open the fuse box and inspect the ignition fuse 1.

Ignition fuse: 15 A

Is the ignition fuse OK?

YES Go to Step 2.NO Go to Step 3.

YES Normal (No DTC exists)

NODTC OUTPUT (Page 27)If DTC can not be output (the ABS indicator light does not flash), go to Step 7.

YES Go to Step 4.NO Replace the ignition fuse.

If a fuse is blown, find the cause of the problem andcorrect it before replacing the fuse.

SAMPLE


Step 41) Turn the ignition switch OFF.2) Disconnect the ABS control unit coupler. (Page 21)3) Turn the ignition switch ON with the ABS control unit coupler

disconnected, measure the voltage between F (O/Y) and N(B/W) at the coupler.

Normal value: Battery voltage (12.0 V and more)



Is the voltage between F and N normal?

Step 51) Turn the ignition switch ON with the ABS control unit coupler

disconnected, measure the voltage between K (Brown) andN (B/W) at the coupler.

Normal value: 8.0 V and more


Is the voltage between K and N normal?

Step 61) Turn the ignition switch OFF.2) Check for continuity between N (B/W) at the coupler and

body ground, also O (B/W) at the coupler and body ground.


Are there continuity between N (O) and body ground?

YES Go to Step 5.

NOInspect the wire harness. (Faulty ignition or ground wire)


YES Go to Step 6.

NO

Inspect the wire harness. (Faulty indicator light wire)Signal fuse or indicator light is blown. (Page 70)


YES Replace the ABS control unit/HU.NO Inspect the wire harness. (Faulty ground wire)


SAMPLE


Step 7The ABS indicator light does not go off1) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the right frame cover. (GSR600K6 8-4)4) Open the fuse box and inspect the ignition fuse 1.

Ignition fuse: 15 A

Is the ignition fuse OK?

Step 81) Turn the ignition switch OFF and disconnect the ABS control

unit coupler. (Page 21)2) Turn the ignition switch ON with the ABS control unit coupler

disconnected, measure the voltage between F (O/Y) and N(B/W) at the coupler.




Is the voltage between F and N normal?


disconnected, measure the voltage between K (Brown) andN (B/W) at the coupler.

Normal value: 8.0 V and more


Is the voltage between K and N normal?

YES Go to Step 8.NO Replace the ignition fuse.


YES Go to Step 9.



YES Go to Step 10.

NOInspect the wire harness. (Faulty indicator light wire)


SAMPLE


Step 101) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the left frame cover. (GSR600K6 8-4)4) Short the mode select coupler terminals (Orange – B/W)

using the special tool.


5) Check for continuity between C (Orange) and N (B/W) at thecoupler.


Is there continuity between C and N?

O

B/W

YES Replace the ABS control unit/HU.

NOInspect the wire harness. (Faulty mode select switch wire)


SAMPLE


DTC (Diagnostic Trouble Code) OUTPUTConnect the special tool to the mode select coupler to output thememorized DTCs on the ABS indicator light.• Turn the ignition switch OFF.• Remove the seat. (GSR600K6 8-3)• Remove the left frame cover. (GSR600K6 8-4)• Connect the special tool to the mode select coupler 1

(Orange – B/W).


• Switch the special tool to ON.• Turn the ignition switch ON.

The ABS indicator light starts flashing to indicate the DTC.

NOTE:* If there is a DTC, the ABS indicator light keeps flashing cycli-

cally and repeatedly.* If there is no DTC, the ABS indicator light keeps lighting on.* If the DTCs are to be output for a long time, remove the

HEAD-LO fuse in order to prevent the battery from discharg-ing.

SAMPLE


UNDERSTANDING THE DTC (Diagnostic Trouble Code)A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and theseparation between the tens and ones are indicated by the light staying off for 1.6 seconds. In addition, theseparation between the start code and the DTC is indicated by the light being off for 3.6 seconds. After thestart code is displayed, DTCs appear from the smallest number code.If no DTCs are memorized, the ABS indicator light keeps lighting up.

1 Initial minimum light ON time (About 2 seconds)2 Error code interval (About 3.6 seconds)3 Main code light ON time (0.4 seconds)4 Main code light OFF time (0.4 seconds)5 Main-sub code interval (1.6 seconds)6 Sub code light ON time (0.4 seconds)7 Sub code light OFF time (0.4 seconds)

ON

OFF

ON

OFF

ON

OFF

OFF

ON

OFF

Output finish

Output start

Code 12 Code 31

ABS indicator light(Malfunction exists)

ABS indicator light(No malfunction exists)

Mode select switch

Brake light switch

Ignition switch

SAMPLE


DTC DELETING AND ABS OPERATION CHECKDTC DELETING• Connect the special tool to the mode select coupler (Orange –

B/W) and output the DTCs.


• While the DTCs are being output, set the special tool to OFF.

• In the DTC deletion mode, switch the ABS test switch fromOFF to ON three times, each time leaving it at ON for morethan 1 second.

The DTC deletion mode starts 12.5 seconds after theswitch is set to OFF.

SAMPLE


ABS OPERATION CHECKAfter deleting the DTCs, repeat the code output procedure andmake sure that no DTCs remain (the ABS indicator light nolonger flashes). If any DTCs remain, perform the appropriateprocedures, then delete the codes. If DTCs are left stored, con-fusion may occur and unnecessary repairs may be made. Afterwards, ride the motorcycle at more than 30 km/h andquickly apply the brakes to check that the ABS activates cor-rectly.

DTC indicationPermitted range of erasing DTC

ABS indicator light

ON

OFF

Mode select switchON

OFF

1 sec. 0.4 sec.0.4 sec. each0.4 sec. each

Cleaning complete

Indicate signal“Cleaning complete”

Cleaningstart

1 sec.1 sec. 1 sec.1 sec. 1 sec.1 sec.1 sec.1 sec.

SAMPLE


SDS CHECKUsing SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance atyour dealer.Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful fortroubleshooting as they can be compared periodically with changes over time or failure conditions of themotorcycle.For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison withthe normal data that have been saved or filed can allow the specific ABS failure to be determined.

• Remove the seat. (GSR600K6 8-3)• Remove the right frame cover. (GSR600K6 8-4)• Set up the SDS tool. (Page 32)

09904-41010: SDS set tool99565-01010-010: CD-ROM Ver.10

NOTE:* Before taking the sample of data, check and clear the Past DTC. (Page 33)* A number of different data under a fixed condition as shown below should be saved or filed as sample.

DATA SAMPLED FROM ABS HU SYSTEM

Check the front wheel speed.XX km/hCheck the front wheel speed.XX km/h

Check the rear wheel speed.XX km/h

Check the battery voltage.XX V

Check the brake switch ON and OFF.

SAMPLE


USE OF SDS DIAGNOSTIC PROCEDURES* Don’t disconnect couplers from ABS HU, the battery cable

from the battery, ABS HU ground wire harness from theengine or main fuse before confirming the malfunction code(self-diagnostic trouble code) stored in memory. Such discon-nection will erase the memorized information in ABS HU mem-ory.

* DTC stored in ABS HU memory can be checked by the SDS.* Be sure to read “CAUTIONS IN SERVICING” (Page 9)

before inspection and observe what is written there.

• Remove the right frame cover. (GSR600K6 8-4)• Set up the SDS tool. (Refer to the SDS operation manual for

further details)• Read the DTC (Diagnostic Trouble Code) and show data

when trouble (displaying data at the time of DTC) according toinstructions displayed on SDS.

• Not only is SDS used for detecting Diagnostic Trouble Codesbut also for reproducing and checking on screen the failurecondition as described by customers using the trigger.

• How to use trigger. (Refer to the SDS operation manual forfurther details.)

09904-41010: SDS set tool99565-01010-0010: CD-ROM Ver.10

SAMPLE


USE OF SDS DIAGNOSIS RESET PROCE-DURE• After repairing the trouble, turn OFF the ignition switch and

turn ON again.• Click the ABS button 1.

• Click the “DTC inspection” button 2.• Check the DTC.• The previous malfunction history code (Past DTC) still

remains stored in the ABS HU. Therefore, erase the historycode memorized in the ABS HU using SDS tool.

NOTE:The DTC is memorized in the ABS HU also when the wire cou-pler of any sensor is disconnected. Therefore, when a wire cou-pler has been disconnected at the time of diagnosis, erase thestored malfunction history code using SDS.

• Click “Clear” 3 to delete history code (Past DTC).

SAMPLE


• Follow the displayed instructions.

• Check that both “Current DTC” 4 and “Past DTC” 5 aredeleted (NIL).

SAMPLE


ACTIVE CONTROL INSPECTION1) Set up the SDS tool. (Refer to the SDS operation manual for

further details.)2) Turn the ignition switch ON.3) Click “ABS” 1.

4) Click “Active control” 2.

5) Click “ABS HU operating” 3.

SAMPLE


6) Click “Next” according to the screen indication.

NOTE:Skip this screen as this vehicle is not equipped with parking brake.

Return Next Cancel Help


SAMPLE


NOTE:* If the front wheel is selected, place the motorcycle on the center stand and lift the front wheel off the

ground using a jack.* Two operators are needed in this work; One should apply a rotational force to the front wheel.



SAMPLE


NOTE:* In normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At

the same time, the ABS HU operating sound will be heard.* The ABS HU motor operates for 6 seconds and then stops automatically.

NOTE:* Inspect the rear brake in the same manner of front brake.* If the ABS does not function, the cause may lie in the ABS control unit/HU.* In checking the rear brake at the time of pressure reduction drive (4/7), “brake lever” appears on the

screen. This is because the present screen shares with other model having front brake only. Therefore, in the case of rear brake pedal equipped vehicle, ignore this instruction and operate the rearbrake pedal.


Return Finish Cancel Help

SAMPLE


DTC TABLE

*1 It goes off after running at more than 10 km/h.*2 The wheel speed sensor lead wire is connected to the ABS control unit, but a short-circuit or faulty conti-

nuity inside the ABS control unit caused this DTC to appear, therefore, the ABS control unit/HU assemblymust be replaced. An insufficient wheel speed sensor output voltage is the cause of a malfunction inwhich the ABS is activated even if the brakes are not suddenly applied. If this occurs frequently eventhough the wheel speed sensor is operating correctly, the ABS control unit/HU assembly should bereplaced.

DTC (Diagnostic

Trouble Code)Malfunction cause

Indicatorstatus Page

None Normal ON *1 —13/C1613 Wheel speed sensor rotor malfunction (F) ON Page 4014/C1614 Wheel speed sensor rotor malfunction (R) ON Page 4222/C1622 ABS actuator circuit malfunction (F) ON Page 4423/C1623 ABS actuator circuit malfunction (R) ON Page 4525/C1625 Wheel speed sensor related malfunction ON Page 4635/C1635 ABS motor malfunction ON Page 4841/C1641 Wheel speed sensor signal malfunction (F) *2 ON Page 4942/C1642 Wheel speed sensor circuit open (F) *2 ON Page 5043/C1643 Wheel speed sensor circuit short (F) *2 ON Page 5244/C1644 Wheel speed sensor signal malfunction (R) *2 ON Page 5345/C1645 Wheel speed sensor circuit open (R) *2 ON Page 5446/C1646 Wheel speed sensor circuit short (R) *2 ON Page 5647/C1647 Supply voltage (Increased) ON Page 5748/C1648 Supply voltage (Decreased) ON Page 5955/C1655 ABS control unit malfunction ON Page 6061/C1661 ABS solenoid malfunction ON Page 61

When disconnecting couplers and turning the ignition switch ON, disconnect the ABS controlunit coupler in order to prevent a DTC from being stored. Each time a resistance is measured,the ignition switch should be set to OFF.

SAMPLE


DTC TROUBLESHOOTINGDTC “13” (C1613): Wheel speed sensor rotor malfunction (F)

Step 11) Inspect the clearance between the front wheel speed sensor

and sensor rotor using the thickness gauge.



Is the clearance OK?

Step 21) Inspect the front wheel speed sensor rotor for damage and

check that no foreign objects are caught in the rotor open-ings.

Is the sensor rotor OK?

Step 31) Check that the front wheel speed sensor is mounted

securely.

Is the sensor mounted securely?

POSSIBLE CAUSE• Front wheel speed sensor rotor distortion• Faulty front wheel speed sensor or wiring discontinuity, etc.

YES Go to Step 2.NO Adjust the clearance.

YES Go to Step 3.NO Clean or replace the sensor rotor.

YES Go to Step 4.

NOTighten the mounting bolts or replace the bracket if necessary.

SAMPLE


Step 41) Inspect the front tire and wheel.

Tire type: BRIDGESTONE BT014F SNTire size: 120/70ZR17M/C (58W)

Tire pressureSolo riding: 250 kPa (2.50 kgf/cm2)Dual riding: 250 kPa (2.50 kgf/cm2)

Wheel runoutService limit (axial and radial): 2.0 mm)

Are the front tire type, tire pressure and wheel runout OK?

YES Replace the ABS control unit/HU.NO Adjust or replace the front tire and wheel.

SAMPLE


DTC “14” (C1614): Wheel speed sensor rotor malfunction (R)

Step 11) Inspect the clearance between the rear wheel speed sensor





Step 21) Inspect the rear wheel speed sensor rotor for damage and



Step 31) Check that the rear wheel speed sensor is mounted securely.


POSSIBLE CAUSE• Rear wheel speed sensor rotor distortion• Faulty rear wheel speed sensor or wiring discontinuity, etc.



YES Go to Step 4.


SAMPLE


Step 41) Inspect the rear tire and wheel.

Tire type: BRIDGESTONE BT014R NTire size: 180/55ZR17M/C (73W)

Tire pressureSolo riding: 250 kPa (2.50 kgf/cm2)Dual riding: 290 kPa (2.90 kgf/cm2)

Wheel runoutService limit (axial and radial): 2.0 mm

Are the rear tire type, tire pressure and wheel runout OK?

YES Replace the ABS control unit/HU.NO Adjust or replace the rear tire and wheel.

SAMPLE


DTC “22” (C1622): ABS actuator circuit malfunction (F)

Step 11) Raise the front wheel off the ground and support the motorcy-

cle with a jack or wooden block.2) Inspect the dragging of the front brake.

Is there any dragging in the front brake?







securely.


POSSIBLE CAUSE• Wire harness discontinuity• Front wheel locking, etc.

YESInspect the front brake master cylinder and the calipers.

NO Go to Step 2.




SAMPLE


DTC “23” (C1623): ABS actuator circuit malfunction (R)

Step 11) Support the motorcycle with its center stand.2) Inspect the dragging of the rear brake.

Is there any dragging in the rear brake?








POSSIBLE CAUSE• Wire harness discontinuity• Rear wheel locking, etc.

YESInspect the rear brake master cylinder and the caliper.

NO Go to Step 2.




SAMPLE


DTC “25” (C1625): Wheel speed sensor related malfunction

Step 11) Check that the specified tires are installed.

Tire type:Front: BRIDGESTONE BT014F SNRear: BRIDGESTONE BT014R N

Tire size:Front: 120/70ZR17M/C (58W)Rear: 180/55ZR17M/C (73W)

Are the tires OK?

Step 21) Make sure the tire pressure for each tire.

(GSR600K6 2-26)

Is the tire pressure for each tire correct?

Step 31) Inspect both wheel speed sensor rotors for damage and


Are the rotors OK?

POSSIBLE CAUSE• Incorrect tire size, poor tire pressure• Deformed wheel, etc.

YES Go to Step 2.NO Use the specified tires.

COLD INFLATION TIRE PRESSURE

SOLO RIDING DUAL RIDINGkPa kgf/cm² kPa kgf/cm²

FRONT 250 2.50 250 2.50REAR 250 2.50 290 2.90

YES Go to Step 3.NO Adjust the tire pressure.

YES Go to Step 4.NO Clean or replace the rotor.

SAMPLE


Step 41) Inspect the clearances of the front and rear wheel speed sen-

sor – sensor rotor using the thickness gauge.



Are the clearances OK?

YES Replace the ABS control unit/HU.NO Adjust the clearance.

SAMPLE


DTC “35” (C1635): ABS motor malfunction

Step 11) Inspect if the pump motor makes turning noise by setting the

ignition switch to ON from OFF when the vehicle stands still.

Does the pump motor make any turning noise?

Step 21) Remove the right frame cover. (GSR600K6 8-4)2) Inspect the ABS motor fuse.

ABS motor fuse: 20 A

Is the HU motor fuse OK?

Step 31) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the frame covers. (GSR600K6 8-4)4) Lift and support the fuel tank. (GSR600K6 5-3)5) Check the ABS control unit coupler for loose or poor con-

tacts. If OK, then disconnect the ABS control unit coupler.6) Measure the voltage between 9 (R/B) and O (B/W) at the

coupler.




Is the voltage between 9 and O normal?

POSSIBLE CAUSE• Faulty HU motor• Faulty wiring, etc.

YESFaulty HU motorReplace the ABS control unit/HU.

NO Go to Step 2.

YES Go to Step 3.NO Replace the HU motor fuse.



NOInspect the wire harness. (Faulty motor power supply or ground wire)


SAMPLE


DTC “41” (C1641): Wheel speed sensor signal malfunction (F)






Step 21) Inspect the front wheel speed sensor rotor for damage and




securely.


POSSIBLE CAUSE• Poor contact in the front wheel speed sensor coupler• Faulty front wheel speed sensor, etc.



YES Go to DTC “42” (C1642). (Page 50)


SAMPLE


DTC “42” (C1642): Wheel speed sensor circuit open (F)

Step 11) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the frame covers. (GSR600K6 8-4)4) Remove the fuel tank. (GSR600K6 5-3)5) Remove the air cleaner box. (GSR600K6 5-13)6) Check the ABS control unit coupler and front wheel speed

sensor coupler for loose or poor contacts. If OK, then discon-nect the ABS control unit coupler.

7) Measure the resistance between B (B/R) and ground at theABS control unit coupler.

Normal value: ∞ Ω (Infinity)

09900-25008: Multi-circuit tester set09900-25009: Needle pointed probe set

Tester knob indication: Resistance (Ω)

Is the resistance between B and ground OK?

Step 21) Disconnect the front wheel speed sensor coupler.2) Measure the resistance between A (Black) and ground at

the front wheel speed sensor coupler.



Is the resistance between A and ground OK?

Step 31) Measure the resistance between 3 (W/R) and ground at the

ABS control unit coupler.



Is the resistance between 3 and ground OK?



YES Inspect the wire harness. (Faulty B/R wire)NO Faulty front wheel speed sensor


ABS control unit coupler(Harness end)

Sensor side


SAMPLE


Step 41) Measure the resistance between B (White) and ground at

the front wheel speed sensor coupler.




Step 51) Check for continuity between B (B/R) on the ABS control unit

coupler and C (B/R) on the front wheel speed sensor cou-pler.

Normal value: Continuity ()

Tester knob indication: Continuity test ()

Is there continuity between B and C?

Step 61) Check for continuity between 3 (W/R) on the ABS control

unit coupler and D (W/R) on the front wheel speed sensorcoupler.



Is there continuity between 3 and D?

Step 71) Connect the front wheel speed sensor coupler.2) Connect three 1.5 V dry cells A in series as shown and make

sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and B (B/R) on the ABS control unit coupler.

Normal value: 3 – 14 mA

Tester knob indication: Current (, 20 mA)

Is the current OK?

YES Inspect the wire harness. (Faulty W/R wire)NO Faulty front wheel speed sensor

YES Go to Step 6.NO Inspect the wire harness. (Faulty B/R wire)

YES Go to Step 7.NO Inspect the wire harness. (Faulty W/R wire)

YES Replace the ABS control unit/HU.NO Faulty front wheel speed sensor.

Sensor side


Harness side


Harness side

DCmA


SAMPLE


DTC “43” (C1643): Wheel speed sensor circuit short (F)


tacts. If OK, then disconnect the ABS control unit coupler.6) Check for continuity between 3 (W/R) and B (B/R) at the

coupler.



Is there continuity between 3 and B?

Step 21) Check for continuity between 2 (B/Y) and 3 (W/R) at the

coupler.


Is there continuity between 2 and 3?


disconnected, measure the voltage between 3 (W/R) and N(B/W) at the coupler.

Normal value: 0 V


Is the voltage between 3 and N normal value?


YESInspect the wire harness. (Faulty sensor wire)Faulty front wheel speed sensor

NO Go to Step 2.

YESInspect the wire harness. (Faulty sensor wire)Faulty wheel speed sensor

NO Go to Step 3.




NOInspect the wire harness. (Faulty sensor signal or power supply wire)


SAMPLE


DTC “44” (C1644): Wheel speed sensor signal malfunction (R)






Step 21) Inspect the rear wheel speed sensor rotor for damage and





POSSIBLE CAUSE• Poor contact in the rear wheel speed sensor coupler• Faulty rear wheel speed sensor, etc.



YES Go to DTC “45” (C1645). (Page 54)


SAMPLE


DTC “45” (C1645): Wheel speed sensor circuit open (R)

Step 11) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the frame covers. (GSR600K6 8-4)4) Lift and support the fuel tank. (GSR600K6 5-3)5) Check the ABS control unit coupler and rear wheel speed

sensor coupler for loose or poor contacts. If OK, then discon-nect the ABS control unit coupler.

5) Measure the resistance between 2 (B/Y) and ground at theABS control unit coupler.




Is the resistance between 2 and ground OK?

Step 21) Disconnect the rear wheel speed sensor coupler.2) Measure the resistance between A (Black) and ground at

the rear wheel speed sensor coupler.



Is the resistance between A and ground OK?

Step 31) Measure the resistance between H (W/Y) and ground at the

ABS control unit coupler.



Is the resistance between H and ground OK?



YES Inspect the wire harness. (Faulty B/Y wire)NO Replace the rear wheel speed sensor.



Sensor side


SAMPLE


Step 41) Measure the resistance between B (White) and ground at

the rear wheel speed sensor coupler.



Step 51) Check for continuity between 2 (B/Y) on the ABS control unit

coupler and C (B/Y) on the rear wheel speed sensor coupler.



Is there continuity between 2 and C?

Step 61) Check the continuity between H (W/Y) on the ABS control

unit coupler and D (W/Y) on the rear wheel speed sensorcoupler.



Is there continuity between H and D?

Step 71) Connect the rear wheel speed sensor coupler.2) Connect three 1.5 V dry cells A in series as shown and make

sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and 2 (B/Y) on the ABS control unit coupler.

Normal value: 3 – 14 mA


Tester knob indication: Current (, 20 mA)

Is the current OK?

YES Inspect the wire harness. (Faulty W/Y wire)NO Replace the rear wheel speed sensor.

Sensor side

YES Go to Step 6.NO Inspect the wire harness. (Faulty B/Y wire)

YES Go to Step 7.NO Inspect the wire harness. (Faulty W/Y wire)

YES Replace the ABS control unit/HU.NO Replace the rear wheel speed sensor.


Harness side


Harness side

DCmA


SAMPLE


DTC “46” (C1646): Wheel speed sensor circuit short (R)


tacts. If OK, then disconnect the ABS control unit coupler.6) Check for continuity between 2 (B/Y) and H (W/Y) at the

coupler.



Is there continuity between 2 and H?

Step 21) Check for continuity between B (B/R) and H (W/Y) at the

coupler.


Is there continuity between B and H?


disconnected, measure the voltage between 2 (B/Y) and N(B/W) at the coupler.

Normal value: 0 V


Is the voltage between 2 and N 0 V?


YESInspect the wire harness. (Faulty sensor wire)Faulty rear wheel speed sensor.

NO Go to Step 2.

YESInspect the wire harness. (Faulty sensor wire)Faulty wheel speed sensor.

NO Go to Step 3.


NOInspect the wire harness. (Faulty sensor signal or power supply wire)




SAMPLE


DTC “47” (C1647): Supply voltage (Increased)

Step 11) Remove the seat. (GSR600K6 8-3)2) Measure the voltage between the + and - battery terminals





Is the voltage over 12 V?

Step 21) Run the engine at 5 000 r/min with the dimmer switch set to

HI.2) Measure the voltage between the + and - battery termi-

nals.

Regulated voltage: 14.0 – 15.5 V at 5 000 r/min



Is the voltage 14.0 – 15.5 V?

POSSIBLE CAUSE• Faulty regulator/rectifier• Faulty ABS control unit• Faulty wire harness, etc.

YES Go to Step 2.NO Charge or replace the battery.

YES Go to Step 3.

NOInspect the regulator/rectifier.(GSR600K6 9-11)

SAMPLE


Step 31) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the frame covers. (GSR600K6 8-4)4) Lift and support the fuel tank. (GSR600K6 5-3)5) Set the immobi-antenna to the ignition switch.6) Check the ABS control unit coupler for loose or poor con-

tacts. If OK, then disconnect the ABS control unit coupler.7) Run the engine at 5 000 r/min with the dimmer switch set to

HI.

8) Measure the voltage between F (O/Y) and N (B/W) at thecoupler.


Is the voltage same as Step 2?




SAMPLE


DTC “48” (C1648): Supply voltage (Decreased)

Step 11) Remove the seat. (GSR600K6 8-3)2) Measure the voltage between the + and - battery terminals





Is the voltage over 12 V?

Step 21) Run the engine at 5 000 r/min with the dimmer switch set to HI.2) Measure the voltage between the + and - battery terminals.

Regulated voltage: 14.0 – 15.5 V at 5 000 r/min


Is the voltage 14.0 – 15.5 V?

Step 31) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the frame covers. (GSR600K6 8-4)4) Lift and support the fuel tank. (GSR600K6 5-3)5) Set the immobi-antenna to the ignition switch.6) Check the ABS control unit coupler for loose or poor con-

tacts. If OK, then disconnect the ABS control unit coupler.7) Run the engine at 5 000 r/min with the dimmer switch set to

HI.

8) Measure the voltage between F (O/Y) and N (B/W) at thecoupler.


Is the voltage same as Step 2?

POSSIBLE CAUSE• Faulty generator or regulator/rectifier• Faulty battery• Faulty wire harness, etc.

YES Go to Step 2.NO Charge or replace the battery.

YES Go to Step 3.

NOInspect the generator and regulator/rectifier. (GSR600K6 9-10 and -11)




SAMPLE


DTC “55” (C1655): ABS control unit malfunction

Step 11) Inspect the clearances of the front and rear wheel speed sen-

sor – sensor rotor using the thickness gauge.



Are the clearances OK?

Step 21) Inspect both of the wheel speed sensor rotors for damage

and check that no foreign objects are caught in the rotoropenings.

Are the rotors OK?

Step 31) Check that the front and rear wheel speed sensors are

mounted securely.

Are the sensors mounted securely?

Step 41) Delete DTCs (Page 29) and repeat the code output pro-

cedure.

If the DTC “55” (C1655) is output again, the ABS control unit/HU should be replaced.

POSSIBLE CAUSEFaulty ABS control unit


YES Go to Step 3.NO Clean or replace the rotor.

YES Go to Step 4.


SAMPLE


DTC “61” (C1661): ABS solenoid malfunction

Step 11) Turn the ignition switch OFF.2) Remove the seat. (GSR600K6 8-3)3) Remove the right frame cover. (GSR600K6 8-4)4) Open the fuse box and inspect the ABS valve fuse 1.

ABS valve fuse: 15 A

Is the ABS valve fuse OK?

Step 21) Lift and support the fuel tank. (GSR600K6 5-3)2) Check the ABS control unit coupler for loose or poor con-

tacts. If OK, then disconnect the ABS control unit coupler.

3) Measure the voltage between 8 (R/Bl) and N (B/W) at thecoupler.




Is the voltage between 8 and N normal?

POSSIBLE CAUSEFaulty solenoid valve or relay

YES Go to Step 2.NO Replace the ABS valve fuse.



NOInspect the wire harness. (Faulty solenoid or ground wire)


SAMPLE


IRREPARABLE MALFUNCTIONSEven though the ABS is operating correctly, a DTC is memo-rized in any of the following conditions.

• After carrying out DTC deleting and ABS operation check(Page 29), explain to the customer that the ABS is oper-ating correctly.

ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATIONFRONT WHEEL SPEED SENSOR/SENSOR ROTORREMOVAL

• Raise the front wheel off the ground and support the motorcy-cle with a jack or wooden block.

• Remove the front wheel speed sensor mounting bolts.• Remove the front wheel assembly. (GSR600K6 8-7)

• Remove the front wheel speed sensor bracket 1.

Conditions

• If the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated.

• Previous malfunctions were repaired, but the DTCs were not deleted.

* The ABS is made up of many precision parts; neversubject it to strong impacts or allow it to becomedirty or dusty.

* Do not hit the sensor rotor when dismounting thewheel.

* The wheel speed sensor cannot be disassembled.

Make sure that the motorcycle is supported securely.

SAMPLE


• Remove the front wheel speed sensor rotor 2.

• Remove the seat. (GSR600K6 8-3)• Remove the frame covers. (GSR600K6 8-4)• Remove the fuel tank side covers. (GSR600K6 8-3)• Remove the fuel tank. (GSR600K6 5-3)• Remove the air cleaner box. (GSR600K6 5-13)• Disconnect the coupler clamp and remove the front wheel

speed sensor.

INSPECTION• Inspect the wheel speed sensor for damage.• Clean the sensor if any metal particle or foreign material stuck

on it.

• Check that no wheel speed sensor rotor teeth are broken andthat no foreign objects are caught in the wheel speed sensor.

INSTALLATIONInstallation is in the reverse order of removal. Pay attention tothe following points:• Install the wheel speed sensor rotor as the letters “50T” face

outside.

When replacing the tire, make sure not to damage thesensor rotor.

SAMPLE


• Align the recess A on the speed sensor bracket with the stop-per B on the right front fork.

• Check the clearance between the front wheel speed sensorand sensor rotor using the thickness gauge.



SAMPLE


Wheel speed sensor

RightLeft

Clearance0.3 – 1.5 mm

SAMPLE


REAR WHEEL SPEED SENSOR/SENSOR ROTORREMOVAL

• Support the motorcycle with its center stand.• Remove the rear wheel speed sensor mounting bolts.• Remove the rear wheel assembly. (GSR600K6 8-32)

• Remove the rear wheel speed sensor rotor 1.

• Remove the seat. (GSR600K6 8-3)• Remove the frame covers. (GSR600K6 8-4)• Remove the fuel tank side covers. (GSR600K6 8-3)• Lift and support the fuel tank. (GSR600K6 5-3)• Disconnect the coupler and remove the rear wheel speed

sensor from the clamps.

* The ABS is made up of many precision parts; neversubject it to strong impacts or allow it to becomedirty or dusty.

* Do not hit the sensor rotor when dismounting thewheel.

* The wheel speed sensor cannot be disassembled.

Make sure that the motorcycle is supported securely.

When replacing the tire, make sure not to damage thesensor rotor.

SAMPLE


INSPECTION• Inspect the wheel speed sensor for damage.• Clean the sensor if any metal particle or foreign material stuck

on it.

• Check that no wheel speed sensor rotor teeth are broken andthat no foreign objects are caught in the wheel speed sensor.

INSTALLATIONInstallation is in the reverse order of removal. Pay attention tothe following points:• Install the wheel speed sensor rotor as the letters “50T” face

outside.

• Install the speed sensor 1 with the sensor clamp 2.

NOTE:Set the clamp with stopper before tightening.

• Check the clearance between the rear wheel speed sensorand sensor rotor using the thickness gauge.



SAMPLE


Rear wheel speed sensor

RightLeft

Clearance

0.3 – 1.5 mm

SAMPLE


ABS CONTROL UNIT/HUREMOVAL

• Remove the seat. (GSR600K6 8-3)• Remove the frame covers. (GSR600K6 8-4)• Remove the fuel tank. (GSR600K6 5-3)• Remove the air cleaner box and throttle body.

(GSR600K6 5-13)• Drain the brake fluid. (GSR600K6 8-55)• Loosen the flare nuts 1 and disconnect the brake pipes.• Disconnect the ABS control unit coupler 2.

• Remove the ABS control unit/HU by removing the mountingbolts.

When storing the brake fluid, seal the container completely and keep away from children.

* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not mix differ-ent types of fluid such as silicone-based or petroleum-based.

* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brakefluid left over from the last servicing or stored for long periods.

* Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materialsetc. and will damage then severely.

* The ABS is made up of many precision parts; never subject it to strong impacts or allow it tobecome dirty or dusty.

* The ABS control unit/HU cannot be disassembled.

SAMPLE


INSTALLATIONInstallation is in the reverse order of removal. Pay attention tothe following points.• Tighten the brake pipe flare nuts to the specified torque.

Brake pipe flare nut: 16 N·m (1.6 kgf-m)

• Bleed air from the brake fluid circuit. (GSR600K6 2-24)

COMBINATION METERLED (LIGHT EMITTING DIODE) INSPECTION• Check that the LEDs (ABS, FI, immobilizer, oil pressure and

engine coolant temp. indicator lights) immediately light upwhen the ignition switch is turned to ON.

• Check that other LEDs (Neutral, High-beam and Turn signalindicator lights) light up/go off by operating each switch.

• If abnormal condition is found, replace the combination meterunit with a new one after checking its wire harness/coupler.

* Route the brake hoses correctly.(Page 73 and 74)

* Make sure to hold the brake pipe when tightening theflare nut, or it may be misaligned.

Never ride the motorcycle before bleeding the air.

SAMPLE


WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATIONWIRE HARNESS ROUTING

*1Set the starter motor lead wire between radia-tor inlet hose and reservoir tank.

*5 Do not twist the lead wires.

*2Pass the handle switch-RH left side of PAIR solenoid valve bracket.

*6Pass through the brake light switch lead wire above the rear brake reservoir tank hose.

*3Pass the IAT sensor branch wire under the delivery pipe.

*7 Do not slack the wiring harness.

*4Cut after clamping and set the lock part down-ward.

*8Pass through the battery - lead wire and starter motor lead wire under the ABS brake pipes.

*1

#1 Injector#2 Injector

Delivery pipe*3

*2

*4*5

PAIR solenoid valve bracket

Taping clamp

Set couplers inside.

Handlebar switch-RH

Speedometer

Reservoir tank Starter motor

Clamp at white tape.

FWD

*6

Clutch cable

Oil pressure switch

Main harness

Stop lamp switch

Oil pressure switch

CKP sensor

Cushion

Throttle cable

Handlebar switch-LH

Headlight

Turn-LH

8 N·m (0.8 kgf-m)

Under ECM

Reservoir tank

CKP sensorBattery lead wire

Starter motor lead wire

Stop lamp switch

Max. 3 mm

5 – 10 mm

30˚ ± 5˚

Speed sensor

Wring harness

ABS brake pipe

10 mm20 mm

Clamp

Clamp

Oil pressure switch

Wiring harnessBrake light switch

Taping clamp

*7Taping clamp

GenaratorGenerator*8

5 – 10 mm

5 – 10 mm

Taping clamp

50 – 70 mm

5 mm

SAMPLE


Guide

Guide Clamp

Clamp

*7

Handlebar-LH switch

Clamp

Ignition switch

Protector

*2

Speedometer

*1

Oil cooler

*3

*5

Clamp Clamp

TO sensor

*4

Handlebar-RH switch lead

26 N·m (2.6 kgf-m)

Wiring harness

GP switch

*6

HO2 sensor

Side-stand switchHO2 sensor

ClampGP switch

Side-stand switchHO2 sensor

GP switchGenerator

Wiring harness

Oil cooler water inlet hoseRadiator outlet hose

Wiring harness

*8

*1Put the lead wire into inside of the frame and pass it upward.

*5 Pass the harnesses backside of the water hose.

*2Set the protector so that clearance comes above the water drain hole.

*6Pass the side-stand lead wire outside of left under cover.

*3 Pass the harness under the hose. *7Pass the wiring harness to regulator/rectifier before assembling the sprocket cover.

*4Fix the bracket to seat rail after to sensor is inserted in the bracket.

*8Pass through the speed sensor lead wire outside of the ABS control unit. (Under the main harness and ABS front piping.)

SAMPLE


FRONT BRAKE HOSE ROUTING

*1 Clamp marking part of brake pipes. *7 Clamp the brake hose firmly.

*2 Pass through the brake hose behind the throttle cables. *8 Set the hoses to clamp firmly.

*3 Pass through the brake hose inside the guide. *9 After the brake hose union has contacted the stopper, tighten the union bolt.

*4 Pass through the brake hose behind the rod. *10 Set the rubber properly.

*5 Set the brake hose firmly. *11 Fit the clamp around the sleeve.Insert the clamp to the hole of fender.

*6 After the brake hose clamp with stopper, tighten the bolt.

*1

*2

*3

*4

*5

*6

*7

*8

*9

*9

*9

*10

*11

35˚

35˚

42˚

14˚

42˚

SAMPLE


REAR BRAKE HOSE ROUTING

*1Pass through the brake hose B under the brake hose A.

*5 Insert the reservoir hose into union to the root.

*2 Set the brake hose to the stopper firmly. *6 Set the clamp firmly.

*3After the brake hose union has contacted to the stopper, tighten the union bolt.

*7 White paint outside.

*4 The ends of clamp should face foreward. *8After the clamp has contacted to the stopper, tighten the bolt.

*7

*8

*6

*3

*3

14˚

*5

*4

*4

*1*2

SAMPLE


FRONT WHEEL SPEED SENSOR INSTALLATION

*1Pass through the sensor lead wire left side of the brake hose.

*6Clamp the sensor lead wire sleeve with the brake hose.

*2 Clamp the sensor lead wire at white marking. *7 Cut the tip of clamp after clamping.

*3Pass through the sensor lead wire upward of the brake hose.

*8 Letters should face outside.

*4Pass through the sensor lead wire in front of the brake hose.

*9Clamp the sensor lead wire at front side of the brake hose. Make clearance from the front fender.

*5Clamp the sensor lead wire sleeve with the brake hose sleeve.

FWD *9

*8

*7

*6

*6

*5

*4

*3*2

*1

SAMPLE


REAR WHEEL SPEED SENSOR INSTALLATION

*1 Cut the tip of clamp after clamping. *3 Clamp the sensor lead wire firmly.*2 Set the clamp with stopper before tightening. *4 Letters should face outside.

*2

*3

*4

*1

SAMPLE


REAR FENDER HEAT SHIELD INSTALLATION

Stick on reverse face

Stick on rib

0 – 2 mm

45 – 50 mm

0 – 1 mm

0 – 1 mm

0 – 2 mm

SAMPLE


SPECIAL TOOLS

NOTE:When order the special tool, please confirm whether it is available or not.

TIGHTENING TORQUE

09900-20602Dial gauge

09900-20701Magnetic stand

09900-2080309900-20806Thickness gauge

09900-20805Tire depth gauge

09900-25008Multi-circuit tester set

09900-25009Needle pointed probe set

09904-41010SDS set tool

09930-82710Mode select switch

99565-01010-010CD-ROM Ver. 10

ITEM N·m kgf-mBrake pipe flare nut 16 1.6SAMPLE


SERVICE DATAVALVE + VALVE GUIDE Unit: mm

CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMITValve diam. IN. 27.2 ----

EX. 22.0 ----Tappet clearance (when cold) IN. 0.10 – 0.20 ----

EX. 0.20 – 0.30 ----Valve guide to valve stem clearance

IN. 0.010 – 0.037 ----EX. 0.030 – 0.057 ----

Valve guide I.D. IN. & EX. 4.000 – 4.012 ----Valve stem O.D. IN. 3.975 – 3.990 ----

EX. 3.955 – 3.970 ----Valve stem deflection IN. & EX. ---- 0.35Valve stem runout IN. & EX. ---- 0.05Valve head thickness IN. & EX. ---- 0.5Valve seat width IN. & EX. 0.9 – 1.1 ----Valve head radial runout IN. & EX. ---- 0.03Valve spring free length IN. ---- 36.2

EX. ---- 36.0Valve spring tension

IN.155 – 179 N (15.8 – 18.3 kgf)

at length 32.55 mm----

EX.146 – 168 N (14.9 – 17.1 kgf)

at length 32.55 mm----

ITEM STANDARD LIMITCam height IN. 35.78 – 35.83 35.48

EX. 34.98 – 35.03 34.68Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 ----Camshaft journal O.D. IN. & EX. 23.959 – 23.980 ----Camshaft runout ---- 0.10Cam chain pin (at arrow “3”) 12th pin ----Cylinder head distortion ---- 0.20

SAMPLE


CYLINDER + PISTON + PISTON RING Unit: mm

CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMITCompression pressure 1 100 – 1 500 kPa

(11 – 15 kgf/cm²)900 kPa

(9 kgf/cm²)Compression pressure difference

----200 kPa

(2 kgf/cm²)Piston to cylinder clearance 0.030 – 0.040 0.120Cylinder bore

67.000 – 67.015Nicks or

ScratchesPiston diam. 66.965 – 66.980

Measure at 15 mm from the skirt end.66.845

Cylinder distortion ---- 0.02Piston ring free end gap 1st T Approx. 5.5 4.4

2nd T Approx. 8.5 6.8Piston ring end gap 1st T 0.06 – 0.21 0.50

2nd T 0.06 – 0.21 0.50Piston ring to groove clearance 1st ---- 0.180

2nd ---- 0.150Piston ring groove width 1st 1.01 – 1.03 ----

2nd 0.81 – 0.83 ----Oil 1.51 – 1.53 ----

Piston ring thickness 1st 0.97 – 0.99 ----2nd 0.77 – 0.79 ----

Piston pin bore I.D. 14.002 – 14.008 14.030Piston pin O.D. 13.995 – 14.000 13.980

ITEM STANDARD LIMITConrod small end I.D. 14.010 – 14.018 14.040Conrod big end side clearance 0.10 – 0.20 0.30Conrod big end width 19.95 – 20.00 ----Crank pin width 20.10 – 20.15 ----Conrod big end oil clearance 0.032 – 0.056 0.080Crank pin O.D. 30.976 – 31.000 ----Crankshaft journal oil clearance 0.016 – 0.040 0.080Crankshaft journal O.D. 29.976 – 30.000 ----Crankshaft thrust bearing thickness

RH 2.425 – 2.450 ----LH 2.350 – 2.500 ----

Crankshaft thrust clearance 0.055 – 0.110 ----Crankshaft runout ---- 0.05

SAMPLE


OIL PUMP

CLUTCH Unit: mm

TRANSMISSION + DRIVE CHAIN Unit: mm Except ratio

ITEM STANDARD LIMITOil pressure (at 60 °C) 200 – 500 kPa

(2.0 – 5.0 kgf/cm²)at 3 000 r/min

----

ITEM STANDARD LIMITClutch lever play 10 – 15 ----Clutch release screw 1/4 turn out ----Drive plate thickness No. 1, 2

and 32.92 – 3.08 2.62

Drive plate claw width No. 1, 2 and 3

13.70 – 13.80 12.90

Driven plate distortion ---- 0.10Clutch spring free length 55.11 52.4

ITEM STANDARD LIMITPrimary reduction ratio 1.926 (79/41) ----Final reduction ratio 3.000 (48/16) ----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) ----

Shift fork-to-groove clearance 0.10 – 0.30 0.50Shift fork groove width 5.0 – 5.1 ----Shift fork thickness 4.8 – 4.9 ----Drive chain Type RK525SMOZ7Y ----

Links 114 links ----20-pitch length

---- 336.5

Drive chain slack (on side-stand) 20 – 30 ----Gearshift lever height 35 – 45 ----

SAMPLE


THERMOSTAT + RADIATOR + FAN + COOLANT

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM STANDARD/SPECIFICATION NOTEThermostat valve opening temperature

Approx. 82 °C ----

Thermostat valve lift 8 mm and over at 95 °C ----ECT sensor resistance 20 °C Approx. 2.45 kΩ ----

50 °C Approx. 0.811 kΩ ----80 °C Approx. 0.318 kΩ ----

110 °C Approx. 0.142 kΩ ----Radiator cap valve opening pressure

93 – 123 kPa(0.93 – 1.23 kgf/cm²)

----

Cooling fan operating temperature OFF→ON Approx. 105 °C ----ON→OFF Approx. 100 °C ----

Engine coolant type Use an antifreeze/coolant compatible with alumi-num radiator, mixed with distilled water only, at the ratio of 50:50.

----

Engine coolant Approx. 2 800 ml ----

ITEM SPECIFICATION NOTEInjector resistance Approx. 12 Ω at 20 °CFuel discharge amount 168 ml and more/10 sec.Fuel pressure regulator operating set pressure

Approx. 300 kPa (3.0 kgf/cm²)

SAMPLE


FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATORITEM SPECIFICATION NOTE

CMP sensor resistance 0.9 – 1.7 k ΩCMP sensor peak voltage 0.7 V and more When crankingCKP sensor resistance 142 – 194 ΩCKP sensor peak voltage 0.5 V and more When crankingIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.7 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ

Opened Approx. 4.4 kΩTP sensor output voltage Closed Approx. 1.1 V

Opened Approx. 4.4 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °CIAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °CAP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 3.6 V at 760 mmHg (100 kPa)TO sensor resistance 16.5 – 22.3 kΩTO sensor voltage Normal 0.4 – 1.4 V

Leaning 3.7 – 4.4 VWhen

leaning 65°GP switch voltage 0.6 V and more From 1st to TopInjector voltage Battery voltageIgnition coil primary peak voltage 85 V and more When crankingSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.6 kΩ

Opened Approx. 4.5 kΩSTP sensor output voltage Closed Approx. 0.6 V

Opened Approx. 4.5 VSTV actuator resistance Approx. 7 ΩPAIR control solenoid valve resis-tance

18 – 22 Ω (at 20 °C – 30 °C)

HO2 sensor output voltage 0.4 V and less at idle speed0.6 V and more at 5 000 r/min

HO2 sensor resistance 4 – 5 Ω at 23 °C

SAMPLE


THROTTLE BODY

ELECTRICAL Unit: mm

ITEM SPECIFICATIONBore size 38 mmI.D. No. 44G0Idle r/min. 1 300 ± 100 r/min.Fast idle r/min. 1 500 – 2 000 r/min. When cold engineThrottle cable play 2.0 – 4.0 mm

ITEM SPECIFICATION NOTEFiring order 1.2.4.3Spark plug

TypeNGK: CR9E

DENSO: U27ESR-NGap 0.7 – 0.8

Spark performance Over 8 at 1 atm.CKP sensor resistance 142 – 194 ΩCKP sensor peak voltage 0.5 V and moreIgnition coil resistance

Primary 1.3 – 1.9 ΩTerminal – Terminal

Secondary 10.8 – 16.2 kΩPlug cap – Terminal

Ignition coil primary peak voltage 85 V and moreGenerator coil resistance 0.2 – 0.9 ΩGenerator no-load performance(When engine is cold)

65 V and more at 5 000 r/min.

Starter motor brush length 10 6.5Regulated voltage (charging out-put)

14.0 – 15.5 V at 5 000 r/min.

Starter relay resistance 3 – 6 ΩGP switch voltage 0.6 V and more (From 1st to top without neutral)Battery Type designa-

tionFTX9-BS

Capacity 12 V 28.8 kC (8 Ah)/10 HRFuse size

HeadlightHI 10 ALO 10 A

Ignition 15 ASignal 10 AFuel 10 AFan 15 AMain 30 A

* ABS motor 20 A* ABS valve 15 A

SAMPLE


WATTAGE Unit: W

BRAKE + WHEEL Unit: mm

ITEM STANDARD/SPECIFICATIONHeadlight HI 60

LO 55Position light 5 × 2Brake light/Taillight LEDTurn signal light 10 × 4License plate light 5Speedometer light LEDTachometer light LEDNeutral indicator light LEDHigh beam indicator light LEDTurn signal indicator light LEDOil pressure/Engine coolant temp. indicator light

LED

FI warning indicator light LEDImmobilizer indicator light LED* ABS indicator light LED

ITEM STANDARD LIMITRear brake pedal height 45 – 55 ----Brake disc thickness Front 4.8 – 5.2 4.5

Rear 4.8 – 5.2 4.5Brake disc runout ---- 0.30Master cylinder bore Front * 14.000 – 14.043 ----

Rear * 12.700 – 12.743 ----Master cylinder piston diam Front * 13.957 – 13.984 ----

Rear * 12.657 – 12.684 ----Brake caliper cylinder bore

FrontLeading * 27.050 – 27.126 ----Trailing * 30.280 – 30.356

Rear 38.180 – 38.256 ----Brake caliper piston diam

FrontLeading * 26.920 – 26.970 ----Trailing * 30.150 – 30.200

Rear 38.098 – 38.148 ----Brake fluid type DOT 4 ----Wheel rim runout Axial ---- 2.0

Radial ---- 2.0Wheel rim size Front 17 M/C × MT 3.50 ----

Rear 17 M/C × MT 5.50 ----Wheel axle runout Front ---- 0.25

Rear ---- 0.25* Wheel speed sensor to sensor

rotor clearanceFront &

Rear0.3 – 1.5 ----

SAMPLE


TIRE

SUSPENSION Unit: mm

ITEM STANDARD LIMITCold inflation tire pressure(Solo riding)

Front250 kPa

(2.50 kgf/cm²)----

Rear250 kPa

(2.50 kgf/cm²)----

Cold inflation tire pressure(Dual riding)

Front250 kPa

(2.50 kgf/cm²)----

Rear290 kPa

(2.90 kgf/cm²)----

Tire size Front 120/70 ZR17 M/C (58 W) ----Rear 180/55 ZR17 M/C (73 W) ----

Tire type Front BRIDGESTONE: BT014F SN ----Rear BRIDGESTONE: BT014R N ----

Tire tread depth(Recommended depth)

Front ---- 1.6Rear ---- 2.0

ITEM STANDARD LIMITFront fork stroke 130 ----Front fork spring free length 334.6 327Front fork oil level (without spring, outer tube fully compressed)

* 110 ----

Front fork oil type SUZUKI FORK OIL G-10 or an equivalent fork oil ----Front fork oil capacity (each leg) * 512 ml ----Front fork inner tube outside diam. 43 ----Front fork spring adjuster 3rd groove from top ----Rear shock absorber spring pre-set length

201.4 ----

Rear shock absorber spring adjuster

4th/7 positions ----

Rear shock absorber damping force adjuster

1 turn out from stiffest position ----

Rear wheel travel 134 ----Swingarm pivot shaft runout ---- 0.3

SAMPLE


FUEL + OILITEM SPECIFICATION NOTE

Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Fuel tank capacity 16.5 LEngine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MAEngine oil capacity Change 3.2 L

Filter change

3.6 L

Overhaul 3.9 L

SAMPLE

WIRING DIAGRAMGSR600AK7Wiring diagrams wire color, refer to GSR600 service manual “WIRE COLOR”.

O B/W

B/W

B/R

B/R

W/R

W/R

B/Y

B/Y

W/Y

W/Y

BB/WB/W

W Gr

Gr B W

B/G

B/G

B/B

lB

/Bl

B/W

B/W B

Y/W

Y/W

W/B

lW

/Bl

Y/B

lY

/Bl

B/W

B/W B/Y

B/Y

YY

/Bl

Y/B

lW

W/B

lW

/Bl

O O/Y

O/Y

B/G

B/G R

R/B

lR

/Bl

O/R

O/R

Bl/B

Bl/B Bl

Bl

G O/Y

O/Y

O/B

O/B Br

Br

Lb

lL

bl

B P G W/B

W/B Bl

Bl Y B

LgB/W

BB/W

BB/W

Y

W

Y

W

B/B

lL

gL

bl

B

YY

/Bl

WW

/Bl

O O/Y

B/G R

R/B

l

O/R

Bl/B Bl

G O/Y

O/B Br

Lb

l

B/B

rG

/Y R

B/B

lB

/Br

B/B

lL

gL

bl

B O W YB

/W B/Y

G/Y

O/B

O/W

B/R

B/B

lY

/GO

/RY

/W

O/B

O/W

B/R

B/B

lY

/GO

/RY

/W

O/B

O/B

O/W

O/W

O/G

O/G

W/B

W/B

Y/G

Y/G O Y/W

Y/WO/B

O/W

O/G

W/B

Y/G O Y/W

B/R

B/W P

B/R

B/W B

G B/W

G B/W

O/G

W/B

O W/B

O/W

O/W

W/B

lW

/Bl

O/W

O/W B

O/W

O/W Y

O/W

O/W G

O/W

O/W

W/G

W/G

O/W

W/B

l

O/W B

O/W Y

O/W G

O/W

W/G

R O Gy

Gy

Br

BrR O Gr

Br

R O O/G

O/G Br

BrR O O

/G Br

R/Y

R/Y

B/W

B/W

O/B

lO

/Bl

O/W

O/W

R/Y

B/W

O/B

lO

/W

Y B G RY B G R

G B/W

B/W

B/W

B/W

B/W

B/W

W/G

W/G

B/Y

B/Y Bl

Bl

B/W

B/W

W/R

W/R

B/B

rB

/Br

Bl/W

Bl/W

Bl/B

Bl/B

Bl/G

Bl/G

W/B

lW

/Bl

B YG

r/W

Gr/

WG

r/B

Gr/

BG

r/Y

Gr/

YG

r/R

Gr/

RY

/GY

/GY

/BY

/B W Y/B

lY

/Bl

Bl/Y

Bl/Y

B/W

B/W Y/R

Y/R Gr

Gr

G/B

lG

/Bl

Br

Br

B/B

rB

/Br

Dg

Dg

G/Y

G/Y P B Y/W

Y/W

B/L

gB

/Lg

G O/G

O/G

R/B

lR

/Bl

G/R

G/R

G/W

G/W

B/Y

B/Y

W/G

W/G R

B/B

lB

/Bl

G/B

G/B

P/B

P/B

B/G

B/G

R/Y

R/Y

O/B

lO

/Bl

Br/

YB

r/Y

P/W

P/W

W/B

W/BG B/W

B/W

B/W

W/G

B/Y Bl

B/W

W/R

B/B

rB

l/WB

l/BB

l/GW

/Bl

B YG

r/W

Gr/

BG

r/Y

Gr/

RY

/GY

/B W Y/B

l

Bl/Y

B/W Y/R Gr

G/B

lB

rB

/Br

Dg

G/Y P B Y/W

B/L

gG O/G

R/B

lG

/RG

/WB

/YW

/G RB

/Bl

G/B

P/B

B/G

R/Y

O/B

lB

r/Y

P/W

W/B

B/B

rB

/Br

Bl/W

Bl/W

Bl/B

Bl/B

Bl/G

Bl/G

Bl/Y

Bl/Y R O/G

O/G

W/R

W/R Gr

Gr

B/W

B/W

B/B

rB

l/WB

l/BB

l/G

Bl/Y R O/G

W/R Gr

B/W B/Y

B/Y

W/R

W/R

W/B

W/B

R/B

lR

/Bl

R/B

R/B Gr

Gr

Br

Br

B/R

B/R O O/Y

O/Y

W/Y

W/Y

B/W

B/W

B/W

B/WB/Y

W/R

W/B

R/B

lR

/B Gr

Br

B/R O O/Y

W/Y

B/W

B/W

R/B

lR

/Bl

Gr

Gr

B/W

B/W

R/B

R/B

O/Y

O/Y

R/B

lG

rB

/WR

/BO

/Y

R/B

lR

/Bl

Gr

Gr

B/W

B/W

R/B

R/B

O/Y

O/Y

R/B

lG

rB

/WR

/BO

/Y

LgB/W

GrB/WW/B

GrGrB/WB/WGr

B/WB/WB/W

BB/W

B

B B B B B

B B B R BB B B R B

B B B

B B B

Bl P

B/W

Y/R

B/W

R/B

B/W

B/W

B/W

R/W

R/W

R/W

B/W

B/W

B/W R R

B/Y

B/Y

Y/G

Y/G R RB/Y

Y/G R R

Y/R

Y/R

B/W

B/W

B/L

gB

/Lg

Y/R

B/W

B/L

g

Y/B

Y/B

O/W

O/W

Y/R

Y/R

R/B

lR

/Bl

Y/B

O/W

Y/R

R/B

l

R BB

/Br

B/B

r

R BB

/Br

Bl

Bl P

B/W

B/WBl P

B/W B/Y

B/Y Br

Br

B/Y Br

G/B

lG

/Bl

G/W

G/W

G/B

lG

/W

B P G W/B Bl Y B

B/B

rB

/Br

G/B

G/B R

B/L

gB

/Lg

P/W

P/W G W/B

W/B R Y/W

Y/W

B/B

rB

/Br

Gr/

WG

r/W

Y/R

Y/R

Gr/

BG

r/B

Y/R

Y/R

Gr/

YG

r/Y

Y/R

Y/R

Gr/

RG

r/R

Y/R

Y/R R P/B

P/B

B/B

rB

/Br

Dg

Dg

B/B

rB

/Br

B/B

rG

/B R

B/L

gP

/W G W/B R Y/W

B/B

r

Gr/

WY

/R

Gr/

BY

/R

Gr/

YY

/R

Gr/

RY

/R R P/B

B/B

r

Dg

B/B

r

W Gr B W

O/W

O/W

B/B

rB

/Br

W/G

W/G WO/W

B/B

rW

/G W

Y/W

W/B

lY

/Bl

B/W B/YB

/GB

/Bl

B/W B

B Bl

BlB Bl

G/R

G/R

O/W

O/W

O/R

O/R BG/R

O/W

O/R B

B/W

B/W Br

Br

Br

Br Y

B/W

B/W

G/Y

G/Y B

R/B

lR

/Bl

Br/

YB

r/Y

PY

/Bl

Y/B

lB

/RB

/R Lg

Lg

O/G

O/G

B/L

gB

/Lg

Bl/B

Bl/B

B/G

B

/G

B/W Br

Br Y

B/W

G/Y B

R/B

lB

r/Y

PY

/Bl

B/R Lg

O/G

B/L

gB

l/BB

/G

B B Br

Br Y

B/B

rB

/Br

G/Y

G/Y B R

Br/

YB

r/Y

P B/Y

B/Y O Lg

Lg

O/G

O/G

R/B

R/B

Bl/B

Bl/B

B/G

B/GB B Br Y

B/B

rG

/Y B RB

r/Y

P B/Y O Lg

O/G

R/B

Bl/B

B/G

BB/W

RR

LgLgBrBr

B/WB/WW/BW/B

B

LgBr

B/WW/B

B

G BG B

R R/B

R/B

R/W

R/W

R/B

lR

/Bl

R R/B

R/W

R/B

l

O B/W

B/R

W/R

B/Y

W/Y

B WB W B WB W

HEADLIGHT

POSITION LIGHT (L)

POSITION LIGHT (R)

FRONT TURN SIGNAL LIGHT (R)

FRONT TURN SIGNAL LIGHT (L)

ECM

HANDLEBAR SWITCH (L)

ECTSENSOR

HO2SENSOR

APSENSOR

ONOFF

OIL PRESSURESWITCH

FUSE BOX RELAY BOX1. HEAD HI2. HEAD LO3. IGNITION 4. SIGNAL5. FUEL6. FAN

10A10A15A10A10A15A

1 2 3 4 5 6

PUSH

PASSINGLIGHTSWITCH

HILO

DIMMERSWITCH

HAZARD SWITCH

PUSH

HORNBUTTON

LPUSH

R

TURN SIGNALLIGHT SWITCH

HORN

CLUTCHSWITCH

FREE

COOLING FANMOTOR

FAN RELAY

OFFON

OFFRUN

OFFONPUSH

HANDLEBAR SWITCH (R)

STARTERBUTTON

FRONT BRAKESWITCH

IGNITION SWITCH

SPEEDSENSOR

FREEPUSH

ONOFF

IGNITIONCOIL #1

IGNITIONCOIL #2

IGNITIONCOIL #3

IGNITIONCOIL #4

PAIRCONTROLSOLENOID

IMMOBILIZERENGINE STOPSWITCH

SPEEDOMETER

REAR BRAKESWITCH

SIDE STAND SWITCH

ONOFFLOCK

P

REAR TURN SIGNAL LIGHT (R)

REAR COMBINATION LIGHT

LICENSE LIGHT

REAR TURN SIGNAL LIGHT (L)

BATTERY

RWS FWS

FUSE BOX

1: MAIN (30 A) STARTER MOTOR STARTER

RELAY

1

GENERATOR

CKPSENSOR

CMPSENSOR

GPSWITCH

REGULATOR/RECTIFIER

TOSENSOR

FUEL PUMPRELAY

FUEL PUMP

M

IAPSENSOR

STV ACTUATOR

INJECTOR#1

INJECTOR#2

INJECTOR#3

INJECTOR#4

TPSENSOR IAT

SENSOR

7: ABS MOTOR (20A) 8: ABS VALVE (15A)

7 8

ABS CONTROL UNIT

SAMPLE

Prepared by

January, 2007

Part No. 99501-36150-01E

Printed in Japan

88SAMPLE

Printed in JapanK7

Documents

GSR600 ABS Service Manual