Suzuki GSX-R 600 - Popular Questions, Answers, Tips & Manuals


Hi, Danny and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Improper valve clearance (too tight)
17. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
18. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
19. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
20. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
21. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
22. Faulty neutral, clutch, kickstand safety switch.
23. Faulty fuel pump or fuse or relay.
24. Faulty or corroded run/stop switch.
25. Tilt sensor needs a reset.
26. Security system not disarming alarm needs a reset.
27. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
What To Do If Your Motorcycle Doesn Start
GSXR 1000 Wont Start Troubleshooting Partzilla com
Suzuki GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki... | 39 views | 0 helpful votes


Hi, Jeff and the usual suspects are:
1. Piston stuck in the caliper due to contamination.
2. Piston stuck in the master cylinder due to contamination.
3. Incorrect DOT # of brake fluid.
4. Warped or bent brake rotor.
5. Incompatible brake pads.
6. Incorrect caliper spacing.
7. Not enough free play at pedal or lever.
8. Collapsed brake line inner lining.
9. Excessive heat buildup due to riding the pedal or lever.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.gixxer.com/forums/66-04-05-gsx-r600-750/255493-front-brakes-locking-up.html
https://www.gsxr.com/11-crashes/198393-front-brakes-locked-up.html
Suzuki GSX R600 Service Manual
https://www.partsfish.com/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2008 Suzuki... | 40 views | 0 helpful votes


I suggest you check the circuit diagram to discover whether the ignition system is a true Capacitive Discharge Ignition or whether the electronic box of tricks is a programmed amplifier that effectively replaces the old fashioned contact breaker.

There are few genuine CDI systems due to the size, complexity and the lethal level of their output. Most systems are the latter type where the current flows through the ignition coil to the amplifier where it is grounded as if by a contact breaker. When the engine rotates a trigger causes the amplifier to suddenly switch off breaking the circuit so the collapsing magnetic field of the coil primary winding induces a spark from the coil secondary winding.

The trigger could be an optical type, a hall effect generator or most commonly a magnetic reluctor type.

When the engine is stationary the programmed amplifier usually switches off after a few seconds preventing the relatively high current flow from overheating the coil and discharging the battery making checking the system difficult to check by conventional methods.

1992 Suzuki... | 35 views | 1 helpful votes


Hi, Trevor if you have changed your engine size, compression ratio, fuel delivery system, air filter size or flow rate, mufflers or exhaust system or a significant change in altitude your carburetors need re-tuning and if your fuel system (gas tank, filters, fuel valve, and carburetor) is contaminated with ethanol sludge, varnish, rust, dirt, water etc. or your bike has been sitting for months or years without running these components must be "PROPERLY" cleaned and reassembled "CORRECTLY" before any adjustments can be made. Tuning your carburetor is fairly simple once you understand the basic principals. You engine is a simple airbox sucking air in and blowing it out, it is finely tuned at the factory for maximum performance once you upset that delicate balance by changing air filters, camshafts or exhaust systems your performance may go down the and the engine may run poorly, you need to compensate the air-fuel mixture in the carburetor in order for the engine to run smoothly and at peak performance. If you are running multi carburetors you need to sync them first and make sure your air cleaner element is clean and dry for paper elements or lightly oiled for foam and meshed elements and properly installed. Here is how and where you compensate trouble: "TIP" if your engine "BOGS" you're not getting enough fuel.
1. Close to 1/8 throttle is managed by the air screw and pilot/slow jet.
2. 1/8 to 1/4 throttle is managed by the air-screw, pilot/slow jet, and throttle slide.
3. 1/4 to 1/2 throttle is managed by the throttle slide and jet needle.
4. 1/2 to 3/4 throttle is managed by the jet needle, needle jet, main jet, and air jet.
5. 3/4 to wide open throttle is managed by the main jet and air jet.
6. A wide open throttle is managed by the main jet.
If you are running lean, spark plug electrode color is white, engine runs hot and feels like it is starving for fuel you need to go up on the jet size or move the c-clip down one notch. If you are running rich, spark plug color is black or dark gray, the engine runs cool, and bogs down when accelerating you need to go down on jet size or move the c-clip up one notch. When your carburetor is properly tuned for maximum performance your spark plug electrode will be a light tan color like coffee with cream. If you prefer fuel economy over performance you can go down on main jet sizes until a satisfactory level of lower performance is acceptable versus MPH, your spark plug color will be whiter and your engine will run warmer. These tuning adjustments will only make improvements if your intake and exhaust system have no air leaks or sealing issues and the entire electrical system is in proper working order and you have no mechanical issues.
For more information about your issue and valuable "FREE" downloads that you will need for viewing and printing please click on the blue links below. Good luck and have a wonderful day.
http://www.dynojet.com/pdf/3123.pdf
Proper procedure for setting Air Fuel Mixture Suzuki GSX Motorcycle Forums...
1993 1998 Suzuki GSX R1100 Service Manual Moto Data Project https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

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1993 Suzuki... | 462 views | 0 helpful votes


Hi, Samuel for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Where is the fuel pressure regulator Suzuki GSX Motorcycle Forums Gixxer...
pressure test on gsxr pressure relief valve
Suzuki 2001 GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


2001 Suzuki... | 1,507 views | 1 helpful votes


Hi, Billy for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
1999 Suzuki GSX 600 wiring diagram Google Search
Suzuki Motorcycle Wiring Diagrams
Suzuki 2001 GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki/suzuki-gsx-owners-manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

1999 Suzuki... | 686 views | 0 helpful votes


Hi, Darren for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
1998 Suzuki GSX 600 wiring diagram Google Search
Suzuki Motorcycle Wiring Diagrams
Suzuki 2001 GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

1998 Suzuki... | 396 views | 1 helpful votes


Hi, Ubreakwefix for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
1996 Suzuki GSX 600 fuel pump location Google Search
97 98 GSXR 600 fuel pump removal
Suzuki 2001 GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


1996 Suzuki... | 175 views | 0 helpful votes


Hi, James_martone make sure the old pushrod is the same length as the new one, for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
How To Replace the Clutch Arm Push Rod on Motorcycle or ATV GSX 600 2 Clutch Push Rod
Suzuki GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e



1998 Suzuki... | 414 views | 0 helpful votes


Hi, Samuel and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, stator, magneto, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Faulty or corroded kill switch.
11. Accelerator pump damaged or not working.
12. Water or dirt in the fuel system, carburetor or filter.
13. Restricted, blocked or kinked fuel line.
14. Fuel tank empty.
15. The gas cap is not venting properly or fuel tank venting system blocked, loosen gas cap and go for a test ride.
16. A failed fuel pump, pressure regulator and or fuel injectors.
17. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
18. Needle and seat stuck closed in the float bowl.
19. Petcock clogged or damaged.
20. Lean angle switch is faulty or needs adjustment.
21. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Bike shuts off while riding Suzuki GSX Motorcycle Forums Gixxer com
bike cut off while riding
Suzuki GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Owner Manual
http://mybikemanuals.com/suzuki

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2001 Suzuki... | 240 views | 1 helpful votes


Hi, Albert before testing any electrical component in the Charging System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
2. To check the regulator unplug it from the stator. Take a test light and clip it to the negative terminal of the battery and then touch first one pin and then the other on the plug that goes to the regulator. If you get even the slightest amount of light from the test light the regulator is toast.
To do this with a meter: black lead to battery ground, red lead to each pin on the plug, start with the voltage scale higher than 12vdc and move voltage scale down in steps for each pin. Any voltage is a bad regulator.
3. On the other part of the disconnected regulator plug. Set the multimeter for Ohms x1 scale and measure for resistance across the pins of the stator. You should read something around 0.1 to 0.2 ohms for a 32 amp system.
4. Then check for continuity between each pin on the plug and frame/engine ground. The meter needle should not move (infinite resistance)(digitals will show infinite resistance) if the meter needle does move (indicating continuity)(digitals will show some resistance), recheck very carefully. If the meter still shows continuity to ground the stator is shorted (bad).
5. Set the meter to read A/C volts higher than 30 volts (the scale setting for voltage should always be higher than the highest voltage you expect or you may fry the meter). Start the bike, and measure from one pin to the other on the plug (DO NOT cross the multimeter probes! - touch them to each other). You should read roughly 16-20 vac per 1,000 rpm.
6. If the battery was good under load test, if the stator is NOT shorted to ground, and the stator is putting out A/C voltage, then the regulator is bad (most likely even if passed step 2)
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
battery not charging on gsxr600
2006 Suzuki GSXR 600 Not Charging
Suzuki GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


2004 Suzuki... | 167 views | 0 helpful votes


Hi, Anonymous and the usual suspects are:
1. Low coolant level.
2. Restricted radiator airflow.
3. Faulty thermostat.
4. Coolant pump or fans inoperative.
5. Vent hose crimped.
6. The air in the coolant and needs bleeding.
7. Engine idling too long or bike moving too slow.
8. Coolant too old needs to be replaced.
9. Faulty temperature sensor, wiring or connector.
10. Radiator veins clogged or corroded needs repair
11. Cooling system leak.
12. Ignition timing retarded.
13. Spark plug heat range too high.
14. Faulty radiator cap.
15. Carburetor jetted too lean.
16. Damaged top end.
17. Blown head gasket.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://forums.13x.com/index.php?threads/2006-gsxr600-overheating.297926/
https://www.youtube.com/watch?v=_e-JWfzeKiA
https://www.manualslib.com/manual/896122/Suzuki-Gsx-R600.html
https://www.partsfish.com/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki/

2006 Suzuki... | 115 views | 0 helpful votes


check the engine oil, it may need changing/topping up

2005 Suzuki... | 50 views | 0 helpful votes


PULL IT ALL DOWN AND TRY PUSHING IT AGAIN, SEE WHERE THE PRESSURE IS, Noit sure what the soloution is mate, but might need a strip down on the clutch cover side as well, oil drained and have a look whats going on.

Suzuki GSX-R 600... | 96 views | 0 helpful votes


Could be ignition fuse. If not that then check the large block connectors which are usually located on the left hand side at the front of the bike behind the cowling beneath the handle bar. These connectors are notorious on GSXR's

2007 Suzuki... | 146 views | 0 helpful votes


Hi, Brandonab684 the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Suzuki GSX R600 Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GSX R600 2003 Owner Manual
Suzuki GSX
Suzuki GSX R600

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2008 Suzuki... | 81 views | 0 helpful votes


Hi, B_joynes your instrument gauges and lights can alert you to most electrical and engine issues they can not warn you about failed engine gaskets or seals so your engine has to resort to old fashion alert methods of colored "SMOKE SIGNALS" here is a breakdown of their meaning:
1. COLORLESS OR SLIGHTLY BLUE SMOKE on start-up means your air/fuel mixture is the right composition and everything is well burnt in your combustion chamber.
2. BLUE SMOKE on startup is usually caused by failed valve seals dripping oil into the combustion chamber when the engine is not running.
3. YELLOW OR BROWNISH SMOKE at start-up means your air/fuel mixture is too lean. Too lean means that there is low fuel but high air mixture in your combustion chamber.
4. WHITE SMOKE on startup may be caused by a blown head gasket allowing coolant to enter the combustion chamber and may start dripping out of the exhaust pipes or mufflers. Smoke while riding is usually caused by worn out or damaged valves, seals, guides, pistons, rings, or cylinder walls.
5. BLACK SMOKE on startup is usually caused by too much fuel in the combustion chamber this can be due to air/fuel mixture adjustment too rich, accelerator pump improperly adjusted, faulty choke or not in the off position, air filter dirty and clogged, faulty carburetor float needle and seat, pilot jet too large, fuel injectors leaking, smoke while riding is usually caused by the main jet being too large or a damaged carburetor.
It should be noted that aggressive or abnormal throttle operation will cause these conditions to manifest themselves exponentially.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the links below. Good luck and have a nice day.
Engine trouble blue smoke thoughts
Blue Smoke
Suzuki GSX R600 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki/suzuki-gsx-owners-manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2006 Suzuki... | 281 views | 0 helpful votes


you need to replace the air temperature sensor. looks like this one https://www.ebay.co.uk/itm/Suzuki-GSXR-TL-SV-AN-600-750-1000-Air-Temperature-Sensor-1996-2009-13650-61B00-/182447458716?hash=item2a7ab7499c:g:-rYAAOSwopRYmblq

1999 Suzuki... | 50 views | 0 helpful votes


It would be inappropriate for me to explain what to do as I do not know if this has been stolen or not.

Suzuki GSX-R 600... | 62 views | 0 helpful votes

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