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2006 SUZUKI GSX-R750 GSX R750 GSXR750 K6 * DIY SERVICE / REPAIR / WORKSHOP MANUAL 06 - PDF DOWNLOAD !!

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2006 SUZUKI GSX-R750 GSX R750 GSXR750 K6 * DIY SERVICE / REPAIR / WORKSHOP MANUAL - PDF DOWNLOAD !!

( VERY HIGH QUALITY FACTORY SERVICE MANUAL - DOWNLOAD !! )

1. Requirements: Adobe PDF Reader
2. Downloadable: YES
3. File Format: PDF
4. Language: English
5. Compatible: All Versions of Windows & Mac

SERVICE MANUAL COVERS:
==================

GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM DIAGNOSIS
FUEL SYSTEM AND THROTTLE
BODY
EXHAUST SYSTEM
COOLING AND
LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
WIRING DIAGRAM

DETAILED CONTENTS:
================

WARNING/CAUTION/NOTE......................................................................... 1- 2
GENERAL PRECAUTIONS.......................................................................... 1- 2
SUZUKI GSX-R750K6 (06-MODEL)............................................................ 1- 4
SERIAL NUMBER LOCATION..................................................................... 1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION....................... 1- 5
FUEL (FOR USA AND CANADA).......................................................... 1- 5
FUEL (FOR OTHER COUNTRIES) ........................................................ 1- 5
ENGINE OIL (FOR USA)........................................................................ 1- 5
ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5
BRAKE FLUID........................................................................................ 1- 5
FRONT FORK OIL.................................................................................. 1- 6
ENGINE COOLANT................................................................................ 1- 6
WATER FOR MIXING............................................................................. 1- 6
ANTI-FREEZE/ENGINE COOLANT....................................................... 1- 6
LIQUID AMOUNT OF WATER/ENGINE COOLANT ............................. 1- 6
BREAK-IN PROCEDURES........................................................................... 1- 7
CYLINDER IDENTIFICATION....................................................................... 1- 7
INFORMATION LABELS.............................................................................. 1- 8
SPECIFICATIONS......................................................................................... 1- 9
DIMENSIONS AND DRY MASS............................................................. 1- 9
ENGINE .................................................................................................. 1- 9
DRIVE TRAIN ......................................................................................... 1- 9
CHASSIS ................................................................................................ 1-10
ELECTRICAL ......................................................................................... 1-10
CAPACITIES .......................................................................................... 1-10

PERIODIC MAINTENANCE SCHEDULE.................................................... 2- 2
PERIODIC MAINTENANCE CHART..................................................... 2- 2
LUBRICATION POINTS........................................................................ 2- 3
MAINTENANCE AND TUNE-UP PROCEDURES....................................... 2- 4
AIR CLEANER....................................................................................... 2- 4
SPARK PLUG........................................................................................ 2- 5
VALVE CLEARANCE............................................................................ 2- 7
ENGINE OIL AND OIL FILTER............................................................. 2-12
EXHAUST CONTROL VALVE .............................................................. 2-13
FUEL LINE............................................................................................. 2-14
ENGINE IDLE SPEED........................................................................... 2-14
THROTTLE VALVE SYNCHRONIZATION........................................... 2-15
EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) .......... 2-15
PAIR (AIR SUPPLY) SYSTEM.............................................................. 2-15
THROTTLE CABLE PLAY.................................................................... 2-15
CLUTCH ................................................................................................ 2-16
COOLING SYSTEM............................................................................... 2-17
DRIVE CHAIN........................................................................................ 2-20
BRAKE .................................................................................................. 2-23
TIRES..................................................................................................... 2-27
STEERING............................................................................................. 2-27
FRONT FORK........................................................................................ 2-28
REAR SUSPENSION ............................................................................ 2-28
EXHAUST PIPE BOLT AND NUT......................................................... 2-29
CHASSIS BOLTS AND NUTS .............................................................. 2-30
COMPRESSION PRESSURE CHECK ........................................................ 2-32
COMPRESSION TEST PROCEDURE.................................................. 2-32
OIL PRESSURE CHECK ............................................................................. 2-33
SDS CHECK................................................................................................. 2-34

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE .......... 3- 2
ENGINE REMOVAL AND INSTALLATION................................................. 3- 3
ENGINE REMOVAL .............................................................................. 3- 3
ENGINE INSTALLATION...................................................................... 3-10
ENGINE DISASSEMBLY............................................................................. 3-14
ENGINE COMPONENTS INSPECTION AND SERVICE............................. 3-27
CYLINDER HEAD COVER.................................................................... 3-27
CMP SENSOR....................................................................................... 3-27
PAIR REED VALVE............................................................................... 3-27
CRANKCASE BREATHER REED VALVE ........................................... 3-28
PCV HOSE............................................................................................. 3-28
CAMSHAFT........................................................................................... 3-29
CAM CHAIN TENSION ADJUSTER ..................................................... 3-31
CAM CHAIN TENSIONER..................................................................... 3-31
CAM CHAIN GUIDE .............................................................................. 3-32
CYLINDER HEAD AND VALVE............................................................ 3-32
CLUTCH ................................................................................................ 3-39
CLUTCH LIFTER................................................................................... 3-40
OIL PUMP.............................................................................................. 3-42
STARTER CLUTCH .............................................................................. 3-42
GENERATOR ........................................................................................ 3-44
WATER PUMP....................................................................................... 3-44
GEARSHIFT SYSTEM........................................................................... 3-44
OIL PRESSURE REGULATOR............................................................. 3-45
OIL STRAINER...................................................................................... 3-45
TRANSMISSION.................................................................................... 3-46
CYLINDER............................................................................................. 3-49
PISTON AND PISTON RING................................................................. 3-50
CRANKCASE ........................................................................................ 3-52
BALANCER SHAFT.............................................................................. 3-62
BALANCER SHAFT JOURNAL BEARING.......................................... 3-62
CRANKSHAFT AND CONROD ............................................................ 3-65
CRANKSHAFT JOURNAL BEARING .................................................. 3-69
CRANKSHAFT THRUST BEARING..................................................... 3-72
ENGINE REASSEMBLY.............................................................................. 3-74

PRECAUTIONS IN SERVICING ................................................................... 4- 3
ELECTRICAL PARTS ............................................................................ 4- 3
FUSE....................................................................................................... 4- 4
ECM/VARIOUS SENSORS .................................................................... 4- 4
ELECTRICAL CIRCUIT INSPECTION PROCEDURE........................... 4- 6
USING THE MULTI-CIRCUIT TESTER.................................................. 4- 9
FI SYSTEM TECHNICAL FEATURES.......................................................... 4-10
INJECTION TIME (INJECTION VOLUME) ............................................ 4-10
COMPENSATION OF INJECTION TIME (VOLUME) ............................ 4-11
INJECTION STOP CONTROL ............................................................... 4-11
FI SYSTEM PARTS LOCATION ............................................................ 4-12
FI SYSTEM WIRING DIAGRAM............................................................. 4-14
ECM TERMINAL ........................................................................................... 4-15
SELF-DIAGNOSIS FUNCTION..................................................................... 4-17
USER MODE .......................................................................................... 4-17
DEALER MODE...................................................................................... 4-18
TPS ADJUSTMENT................................................................................ 4-20
FAIL-SAFE FUNCTION ................................................................................ 4-21
FI SYSTEM TROUBLESHOOTING .............................................................. 4-23
CUSTOMER COMPLAINT ANALYSIS .................................................. 4-23
VISUAL INSPECTION............................................................................ 4-24
SELF-DIAGNOSTIC PROCEDURES..................................................... 4-25
SELF-DIAGNOSIS RESET PROCEDURE............................................. 4-25
USE OF SDS DIAGNOSTIC PROCEDURES ........................................ 4-26
USE OF SDS DIAGNOSIS RESET PROCEDURE ................................ 4-27
SHOW DATA WHEN TROUBLE
(DISPLAING DATA AT THE TIME OF DTC) ......................................... 4-28
MALFUNCTION CODE AND DEFECTIVE CONDITION ....................... 4-29
C11 (P0340) CMP SENSOR CIRCUIT MALFUNCTION.................... 4-33
C12 (P0335) CKP SENSOR CIRCUIT MALFUNCTION .................... 4-35
C13 (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION............... 4-38
C14 (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION ................ 4-44
C15 (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION.............. 4-49
C21 (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION ............... 4-53
C22 (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION................ 4-57
C23 (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION................ 4-63
C24 (P0351), C25 (P0352), C26 (P0353) or C27 (P0354)
IGNITION SYSTEM MALFUNCTION..................................................... 4-66
C28 (P1655) STV ACTUATOR CIRCUIT MALFUNCTION................ 4-67
C29 (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION.............. 4-70

FUEL DELIVERY SYSTEM.......................................................................... 5- 2
FUEL SYSTEM............................................................................................. 5- 3
FUEL TANK LIFT-UP............................................................................ 5- 3
FUEL TANK REMOVAL........................................................................ 5- 4
FUEL TANK INSTALLATION ............................................................... 5- 4
FUEL PRESSURE INSPECTION.......................................................... 5- 4
FUEL PUMP INSPECTION ................................................................... 5- 5
FUEL DISCHARGE AMOUNT INSPECTION ....................................... 5- 6
FUEL PUMP RELAY INSPECTION ...................................................... 5- 7
FUEL PUMP AND FUEL FILTER REMOVAL....................................... 5- 8
FUEL MESH FILTER INSPECTION AND CLEANING ......................... 5-10
FUEL PUMP AND FUEL MESH FILTER INSTALLATION................... 5-10
THROTTLE BODY ....................................................................................... 5-13
CONSTRUCTION .................................................................................. 5-13
AIR CLEANER BOX REMOVAL AND INSTALLATION....................... 5-14
THROTTLE BODY REMOVAL.............................................................. 5-15
THROTTLE BODY DISASSEMBLY...................................................... 5-16
THROTTLE BODY CLEANING............................................................. 5-18
INSPECTION ......................................................................................... 5-18
THROTTLE BODY REASSEMBLY....................................................... 5-19
THROTTLE BODY INSTALLATION ..................................................... 5-21
STP SENSOR ADJUSTMENT .............................................................. 5-22
FUEL INJECTOR REMOVAL................................................................ 5-23
FUEL INJECTOR INSPECTION............................................................ 5-23
FUEL INJECTOR INSTALLATION ....................................................... 5-23
FAST IDLE............................................................................................. 5-24
FAST IDLE ADJUSTMENT................................................................... 5-24
THROTTLE VALVE SYNCHRONIZATION........................................... 5-26
THROTTLE POSITION SENSOR (TPS) SETTING............................... 5-27

EXHAUST SYSTEM..................................................................................... 6- 2
EXHAUST CONTROL SYSTEM ........................................................... 6- 2
OPERATION.......................................................................................... 6- 3
EXCVA (EXHAUST CONTROL VALVE ACTUATOR)
AND EXCV (EXHAUST CONTROL VALVE)............................................... 6- 4
EXCVA REMOVAL................................................................................ 6- 4
EXCVA PULLEY INSPECTION............................................................. 6- 5
EXCVA INSTALLATION ....................................................................... 6- 5
EXCVA INSPECTION............................................................................ 6- 6
EXCV CABLE REPLACEMENT............................................................ 6- 7
EXCVA ADJUSTMENT ......................................................................... 6- 8
EXCV/EXHAUST PIPE, MUFFLER REMOVAL.................................... 6-10
EXCV INSPECTION .............................................................................. 6-12
EXCV/EXHAUST PIPE, MUFFLER INSTALLATION ........................... 6-12

ENGINE COOLANT ..................................................................................... 7- 2
COOLING CIRCUIT ..................................................................................... 7- 3
COOLING CIRCUIT INSPECTION........................................................ 7- 3
RADIATOR AND WATER HOSES .............................................................. 7- 4
RADIATOR REMOVAL ......................................................................... 7- 4
RADIATOR CAP INSPECTION............................................................. 7- 4
RADIATOR INSPECTION AND CLEANING......................................... 7- 4
RADIATOR INSTALLATION................................................................. 7- 5
WATER HOSE INSPECTION................................................................ 7- 5
COOLING FAN............................................................................................. 7- 6
REMOVAL ............................................................................................. 7- 6
INSPECTION ......................................................................................... 7- 6
INSTALLATION..................................................................................... 7- 6
COOLING FAN RELAY INSPECTION.................................................. 7- 7
ECT SENSOR .............................................................................................. 7- 7
REMOVAL ............................................................................................. 7- 7
INSPECTION ......................................................................................... 7- 7
INSTALLATION..................................................................................... 7- 8
THERMOSTAT............................................................................................. 7- 9
REMOVAL ............................................................................................. 7- 9
INSPECTION ......................................................................................... 7- 9
INSTALLATION..................................................................................... 7-10
WATER PUMP ............................................................................................. 7-11
REMOVAL AND DISASSEMBLY ......................................................... 7-11
INSPECTION ......................................................................................... 7-13
REASSEMBLY AND INSTALLATION.................................................. 7-14
LUBRICATION SYSTEM............................................................................. 7-17
OIL COOLER......................................................................................... 7-17
OIL PRESSURE .................................................................................... 7-18
OIL FILTER............................................................................................ 7-18
OIL PRESSURE REGULATOR............................................................. 7-18
OIL STRAINER...................................................................................... 7-18
OIL JET.................................................................................................. 7-18
OIL PUMP.............................................................................................. 7-18
OIL PRESSURE SWITCH ..................................................................... 7-18
ENGINE LUBRICATION SYSTEM CHART .......................................... 7-19
ENGINE LUBRICATION SYSTEM........................................................ 7-20

EXTERIOR PARTS ...................................................................................... 8- 3
FASTENER REMOVAL AND INSTALLATION..................................... 8- 3
BODY COWLING COVER AND LOWER BRACKET COVER............. 8- 5
INNER UNDER COWLING.................................................................... 8- 5
UNDER COWLING................................................................................ 8- 5
SCREEN ................................................................................................ 8- 6
BODY COWLING .................................................................................. 8- 6
AIR INTAKE PIPE ................................................................................. 8- 7
COWLING BRACE................................................................................ 8- 7
FRONT SEAT ........................................................................................ 8- 7
FUEL TANK LOWER SIDE COVER ..................................................... 8- 7
REAR SEAT/SEAT TAIL COVER......................................................... 8- 8
FRAME COVER..................................................................................... 8- 8
FRONT WHEEL ........................................................................................... 8- 9
CONSTRUCTION .................................................................................. 8- 9
REMOVAL AND DISASSEMBLY ......................................................... 8-10
INSPECTION ......................................................................................... 8-12
REASSEMBLY AND INSTALLATION.................................................. 8-13
FRONT FORK .............................................................................................. 8-17
CONSTRUCTION .................................................................................. 8-17
REMOVAL AND DISASSEMBLY ......................................................... 8-18
INSPECTION ......................................................................................... 8-21
REASSEMBLY ...................................................................................... 8-22
INSTALLATION..................................................................................... 8-26
SUSPENSION SETTING ....................................................................... 8-27
STEERING DAMPER................................................................................... 8-28
CONSTRUCTION .................................................................................. 8-28
REMOVAL ............................................................................................. 8-29
INSPECTION ......................................................................................... 8-29
INSTALLATION..................................................................................... 8-29
STEERING ................................................................................................... 8-30
CONSTRUCTION .................................................................................. 8-30
REMOVAL ............................................................................................. 8-31
INSPECTION AND DISASSEMBLY ..................................................... 8-32
REASSEMBLY ...................................................................................... 8-33
INSTALLATION..................................................................................... 8-33
STEERING TENSION ADJUSTMENT .................................................. 8-35
HANDLEBARS............................................................................................. 8-36
CONSTRUCTION .................................................................................. 8-36
REMOVAL ............................................................................................. 8-36
INSTALLATION..................................................................................... 8-37
REAR WHEEL.............................................................................................. 8-40
CONSTRUCTION .................................................................................. 8-40
REMOVAL ............................................................................................. 8-41
INSPECTION AND DISASSEMBLY ..................................................... 8-42
REASSEMBLY AND INSTALLATION.................................................. 8-44
REAR SHOCK ABSORBER........................................................................ 8-48
CONSTRUCTION .................................................................................. 8-48

CAUTIONS IN SERVICING ......................................................................... 9- 3
CONNECTOR........................................................................................ 9- 3
COUPLER.............................................................................................. 9- 3
CLAMP .................................................................................................. 9- 3
FUSE...................................................................................................... 9- 3
SEMI-CONDUCTOR EQUIPPED PART ............................................... 9- 4
BATTERY .............................................................................................. 9- 4
CONNECTING THE BATTERY............................................................. 9- 4
WIRING PROCEDURE.......................................................................... 9- 4
USING THE MULTI-CIRCUIT TESTER................................................. 9- 5
LOCATION OF ELECTRICAL COMPONENTS ......................................... 9- 6
CHARGING SYSTEM ................................................................................. 9- 8
TROUBLESHOOTING........................................................................... 9- 8
INSPECTION ......................................................................................... 9- 9
STARTER SYSTEM AND SIDE-STAND/
IGNITION INTERLOCK SYSTEM ............................................................... 9-12
TROUBLESHOOTING........................................................................... 9-12
STARTER MOTOR REMOVAL............................................................. 9-13
STARTER MOTOR DISASSEMBLY..................................................... 9-14
STARTER MOTOR INSPECTION......................................................... 9-14
STARTER MOTOR REASSEMBLY...................................................... 9-15
STARTER RELAY INSPECTION.......................................................... 9-16
SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION .. 9-17
IGNITION SYSTEM ..................................................................................... 9-20
IMMOBILIZER (Except for E-03, 28, 33).............................................. 9-21
TROUBLESHOOTING........................................................................... 9-23
INSPECTION ......................................................................................... 9-25
COMBINATION METER ............................................................................. 9-29
DESCRIPTION....................................................................................... 9-29
REMOVAL AND DISASSEMBLY ......................................................... 9-30
INSPECTION ......................................................................................... 9-31
LAMPS ........................................................................................................ 9-35
HEADLIGHT, BRAKE LIGHT/TAILLIGHT,
LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT......................... 9-35
RELAYS ...................................................................................................... 9-37


TROUBLESHOOTING ............................................................................... 10- 2
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION...... 10- 2
ENGINE ............................................................................................... 10- 6
RADIATOR (COOLING SYSTEM) ...................................................... 10-12
CHASSIS ............................................................................................. 10-13
BRAKES.............................................................................................. 10-14
ELECTRICAL ...................................................................................... 10-15
BATTERY ............................................................................................ 10-16
WIRING HARNESS, CABLE AND HOSE ROUTING................................ 10-17
WIRING HARNESS ROUTING............................................................ 10-17
HO2 SENSOR HARNESS ROUTING (For E-02, 19).......................... 10-20
CABLE ROUTING ............................................................................... 10-21
FUEL TANK HOSE ROUTING............................................................ 10-22
COOLING SYSTEM HOSE ROUTING................................................ 10-23
FRONT BRAKE HOSE ROUTING ...................................................... 10-24
REAR BRAKE HOSE ROUTING ........................................................ 10-25
FUEL TANK INSTALLATION ............................................................. 10-26
COWLING INSTALLATION ................................................................ 10-26
FRAME COVER INSTALLATION ....................................................... 10-27
SEAT LOCK CABLE ROUTING ......................................................... 10-28
REAR FENDER INSTALLATION........................................................ 10-28
SIDE-STAND INSTALLATION............................................................ 10-30
UNDER COWLING CUSHION RUBBER/
HEAT SHIELD INSTALLATION.......................................................... 10-30
FRONT FOOTREST INSTALLATION................................................. 10-31
REAR VIEW MIRROR INSTALLATION.............................................. 10-32
SPECIAL TOOLS ................................................................................ 10-33
TIGHTENING TORQUE ............................................................................. 10-37
ENGINE ............................................................................................... 10-37
FI SYSTEM AND INTAKE AIR SYSTEM............................................ 10-38
COOLING SYSTEM............................................................................. 10-38
CHASSIS ............................................................................................. 10-39
TIGHTENING TORQUE CHART......................................................... 10-40
SERVICE DATA......................................................................................... 10-41

EMISSION CONTROL SYSTEMS...............................................................11- 2
FUEL INJECTION SYSTEM..................................................................11- 2
CRANKCASE EMISSION CONTROL SYSTEM...................................11- 3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM).............11- 4
NOISE EMISSION CONTROL SYSTEM...............................................11- 5
PAIR (AIR SUPPLY) SYSTEM AND
EMISSION CONTROL SYSTEM INSPECTION ..........................................11- 6
PAIR HOSES.........................................................................................11- 6
PAIR REED VALVE ..............................................................................11- 6
PCV HOSE ............................................................................................11- 6
PAIR CONTROL SOLENOID VALVE...................................................11- 7
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .......................................11- 8
HO2 SENSOR INSPECTION (For E-02, 19) ...............................................11- 9

--------------------------------------------------------------------------------------

DESCRIPTION:
=========

COVERS ALL MODELS & ALL REPAIRS A-Z

THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.

COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!

YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE CD-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.

ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES!

FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.

ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!

--------------------------------------------------------------------------------------

RELATED KEYWORDS:

2006 Suzuki Gsx-r750 06 K6 Service Manual Download 2006 Suzuki Gsx R750 K6 Service Manual Download Suzuki Gsx-r750 K6 Motorcycle Service Manual 2006

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