Basic Information Identification Make: Suzuki Model: GSXR600 Year: 2004-2005 Generation Model Generation: Third Generation (K4/K5) Codes Internal Chassis Codes: RK021 (2004), RK022 (2005) Introduction Market Position Motorcycle Segment: Supersport / Sportbike Competitive Analysis Key Competitors: Yamaha YZF-R6, Honda CBR600RR, Kawasaki ZX-6R Key Features Model Philosophy: The 2004-2005 GSXR600 represented a significant evolution in Suzuki's 600cc supersport offering, focusing on a balance of accessible power, sharp handling, and technological advancements for its era. Manual Value Proposition: This manual provides the detailed technical information necessary for professional-level maintenance, repair, and troubleshooting, empowering owners and technicians to maintain peak performance and longevity of the GSXR600. Manual Details Coverage Areas Supported Models: Suzuki GSXR600 (2004-2005) Page Count Total Pages: 465 Manual Type Manual Classification: Workshop Service Repair Manual Language Primary Language: English Format Digital Format: PDF Manual Coverage Systems Covered Engine Systems: Engine disassembly and reassembly, valve clearance adjustment, timing chain inspection, cooling system, lubrication system, fuel injection system, ignition system, exhaust system. Drivetrain Systems: Transmission disassembly and reassembly, clutch operation and maintenance, gear shift mechanism. Chassis Systems: Front fork (telescopic, cartridge type) overhaul and adjustment, rear shock absorber inspection and adjustment, swingarm inspection, steering head bearing maintenance, wheel bearing inspection, brake system (hydraulic disc, front and rear) overhaul, caliper and master cylinder servicing. Electrical Systems: Wiring diagrams, lighting system, starting system, charging system (stator, regulator/rectifier), ignition system components, instrument panel, sensors, ECU. Bodywork And Trim: Fairing removal and installation, seat removal, fuel tank removal and installation, tail section, front fender, rear fender. Procedures Included Routine Maintenance: Oil and filter change, air filter cleaning/replacement, spark plug replacement, coolant flush and replacement, brake fluid flush and replacement, chain lubrication and adjustment, tire pressure checks, battery maintenance. Troubleshooting: Diagnostic procedures for common starting issues, running problems, electrical faults, braking system malfunctions, and more. Repair And Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all major motorcycle systems. Technical Depth Diagnostic Capabilities: Advanced diagnostics including sensor testing, circuit continuity checks, and interpretation of system behaviors. Engine Rebuild Level: Comprehensive engine disassembly, blueprinting, and reassembly procedures, including piston, connecting rod, crankshaft, and cylinder head service. Special Tool References: Identification and usage of specific Suzuki special tools required for certain adjustments and repairs, often including part numbers. Manual Specifications File Format Digital Delivery Method: Electronic Delivery via Email Print Quality Printable Format: Yes Binding Type Physical Binding: Not Applicable (Digital PDF) Paper Type Physical Paper Type: Not Applicable (Digital PDF) Engine Specifications Primary Engine Engine Type: Inline Four-Cylinder, DOHC, 16-Valve Displacement: 599 cc (36.5 cu in) Bore X Stroke: 72.0 mm x 73.3 mm Compression Ratio: 12.5:1 Performance Horsepower Estimate: Approx. 115-120 hp @ 13,000 rpm (crank) Torque Estimate: Approx. 46-48 lb-ft @ 11,500 rpm (crank) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Twin Injectors per Cylinder Throttle Body Size: 42 mm Ignition System Ignition Type: Digital CDI with Electronic Advance Cooling System Cooling Method: Liquid-Cooled Lubrication System Lubrication Type: Wet Sump Transmission Standard Transmission Type: 6-Speed Constant Mesh Features Clutch Type: Wet, Multi-Plate Dimensions Exterior Overall Length: Approx. 2050 mm (80.7 in) Overall Width: Approx. 715 mm (28.1 in) Overall Height: Approx. 1135 mm (44.7 in) Weights Dry Weight: Approx. 163 kg (359 lbs) Wet Weight: Approx. 187 kg (412 lbs) Fuel Tank Capacity: 17.5 L (4.6 US gal) Safety Features Ratings Crash Test Ratings: Not applicable for motorcycles in the same manner as automobiles. Active Features Braking System Type: Hydraulic Dual Disc (Front), Hydraulic Single Disc (Rear) Front Brake Caliper Type: Radial-mount four-piston calipers Suspension Type: Inverted Telescopic, Coil Spring, Oil Damped (Front), Link Type, Coil Spring, Oil Damped (Rear) Technology Features Infotainment Instrument Panel Features: Digital speedometer, analog tachometer, fuel gauge, coolant temperature gauge, clock, trip meters, gear position indicator (on some models/aftermarket), LED backlighting. Driver Assistance Traction Control: Not equipped ABS: Not equipped as standard on this model year. Connectivity Electronic Controls: ECU controlled ignition and fuel injection mapping. Maintenance Service Intervals Engine Oil Change Interval: Every 3,500 miles (5,600 km) or 6 months, whichever comes first. Air Filter Inspection Interval: Every 3,500 miles (5,600 km). Spark Plug Replacement Interval: Every 7,000 miles (11,200 km). Coolant Replacement Interval: Every 2 years or 10,000 miles (16,000 km). Brake Fluid Replacement Interval: Every 2 years. Fluid Specifications Engine Oil Type: API SG, SH, SJ or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended. Engine Oil Capacity: 3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change. Coolant Type: Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze with demineralized water, 50:50 mixture). Brake Fluid Type: DOT 4 Known Issues Typical Wear Items: Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings due to the performance-oriented nature of the bike. Common Faults Or Concerns: Some owners have reported potential...