The Suzuki GSXR600, specifically the K4/K5 generation produced between 2004 and 2005, represents a significant evolution in the middleweight supersport motorcycle class. Known for its potent 599 cc four-stroke, liquid-cooled engine, this model delivers approximately 110-115 horsepower, channeled through a precise 6-speed transmission. Its engineering prowess is evident in the advanced aluminum twin-spar frame, inverted telescopic front forks, and linkage-type rear suspension, all contributing to exceptional handling and rider feedback. Designed for performance-oriented riding, the GSXR600 (Gixxer) offers a dynamic and engaging experience, building upon Suzuki's rich heritage in motorcycle racing. This comprehensive workshop service manual is your essential guide for the repair and overhaul of the Suzuki GSXR600 (K4/K5). Covering a wide array of systems, including detailed procedures for engine disassembly and reassembly, fuel and ignition systems, lubrication, electrical components, transmission, suspension, brakes, and more, this manual ensures you have the information needed for meticulous maintenance. It provides step-by-step instructions for routine servicing, component removal and installation, troubleshooting common issues, and references special tools. With its in-depth coverage, this 465-page English-language manual is an indispensable resource for both professional technicians and dedicated enthusiasts seeking to maintain and optimize their GSXR600. 🏷️ Basic Information Identification Make: Suzuki Model: GSXR600 (Gixxer) Year: 2004-2005 Codes Chassis Code: K4/K5 👋 Introduction Market Position Description: The Suzuki GSXR600 (K4/K5 generation) was a highly regarded middleweight supersport motorcycle known for its performance, handling, and race-derived technology. This manual targets owners and technicians aiming for precise maintenance and repair. Competitive Analysis Competitors: Honda CBR600RR, Yamaha R6, Kawasaki ZX-6R Key Features Advantage: Provides detailed, manufacturer-specific information for optimal servicing and repair, enabling professional-quality results. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Overhaul Page Count Total Pages: 465 Manual Type Type: Workshop Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, reassembly, tuning Fuel System: Carburetor settings, fuel pump, lines, injectors (if applicable) Ignition System: Ignition timing, spark plugs, coils, CDI unit Lubrication System: Oil pump, oil filter, oil passages, oil change procedures Exhaust System: Muffler, catalytic converter (if applicable), exhaust headers Electrical System: Wiring diagrams, charging system, lighting, starter, battery Body: Fairings, seat, fuel tank, fenders, mirrors Transmission: Gearbox disassembly, inspection, reassembly, clutch Suspension: Front fork disassembly, adjustment, rear shock absorber, linkages Brakes: Brake caliper overhaul, master cylinder, brake lines, pad replacement Wheels And Tires: Wheel bearing replacement, tire pressure, wheel balance Cooling System: Radiator, cooling fan, coolant hoses, thermostat Frame And Steering: Steering head bearing replacement, frame inspection Proprietary Components: Includes instructions for proprietary Suzuki components and references for third-party parts if integrated. Procedures Included Maintenance: Routine servicing, tune-ups, fluid changes, filter replacements Removal Installation: Detailed procedures for component removal and installation Assembly Disassembly: Step-by-step guides for major component overhauls Troubleshooting: Diagnostic procedures for common issues Special Tool Identification: References to specific Suzuki special tools and their application Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIYers Diagnostic Capabilities: Includes troubleshooting guides for electrical and mechanical issues Manual Type Purpose: To enable technicians to perform accurate repairs and maintenance, ensuring optimal vehicle performance and longevity. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF Searchability: Searchable text for quick information retrieval Print Quality Printable: Yes Binding Type Binding: Digital (PDF Download) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Type: 90° V-twin, Four-stroke, Liquid-cooled Displacement: 599 cc Bore X Stroke: 72.0 mm x 48.6 mm Valve Train: DOHC, 16 valves (4 per cylinder) Compression Ratio: 12.4:1 Starting System: Electric starter Performance Horsepower: Approx. 110-115 hp (at crank) Torque: Approx. 48-50 lb-ft (at crank) Fuel System Induction: Mikuni BSR32 flat-slide carburetors Fuel Capacity: 4.4 US gal (16.5 L) Lubrication System Oil Capacity With Filter: 3.2 US qt (3.0 L) Cooling System Coolant Type: Suzuki Super Long Life Coolant (or equivalent) Ignition Ignition Type: Electronic ignition (CDI) Exhaust Exhaust System Type: 2-into-1-into-2 stainless steel 🔧 Transmission Standard Type: 6-speed, constant mesh Features Clutch: Wet multi-plate Final Drive: O-ring sealed chain Gear Ratios: Detailed in manual (specific ratios for each gear) Fluid Specifications Transmission Oil Type: API GL-4 SAE 10W-40 motorcycle gear oil 📐 Dimensions Exterior Length: 2045 mm (80.5 in) Width: 715 mm (28.1 in) Height: 1130 mm (44.5 in) Wheelbase: 1405 mm (55.3 in) Ground Clearance: 130 mm (5.1 in) Seat Height: 830 mm (32.7 in) Weights Dry Weight: 163 kg (359 lbs) Curb Weight: 187 kg (412 lbs) Weight Distribution: Front: 52%, Rear: 48% (approx.) Payload Capacity: Not specified (Designed for solo rider) Wheels And Tires Front Tire: 120/70ZR17M/C (58W) Rear Tire: 180/55ZR17M/C (73W) Front Wheel: 3.50 x 17 Rear Wheel: 5.50 x 17 🛡️ Safety Features Active Features Braking System: Dual hydraulic disc front, single hydraulic disc rear Front Brakes: 2x 300mm discs with 4-piston calipers Rear Brakes: 1x 220mm disc with 2-piston caliper Front Suspension: Inverted telescopic,...