Suzuki GSX-R600 User Manual

1D-72 Engine Mechanical:
Piston Ring Free End Gap and Piston Ring End Gap
Measure the piston ring free end gap using vernier
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Special tool
(A): 09900–20102 (Vernier calipers (1/20 mm,
200 mm))
Piston ring free end gap
Service limit (1st): 4.4 mm (0.17 in)
Service limit (2nd): 6.0 mm (0.24 in)
Special tool
(B): 09900–20803 (Thickness gauge)
Piston ring end gap
Service limit (1st): 0.50 mm (0.020 in)
Service limit (2nd): 0.50 mm (0.020 in)
Piston Pin and Pin Bore
Measure the piston pin bore inside diameter using the
small bore gauge. If either is out of specification or the
difference between these measurements surpass limits,
replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000 mm, 1
mm))
(B): 09900–22401 (Small bore gauge (10 – 18
mm))
Piston pin bore
Service limit: 14.030 mm (0.5524 in)
Measure the piston pin outside diameter at three
positions using the micrometer. If any of the
measurements are out of specification, replace the
piston pin.
Special tool
(C): 09900–20205 (Micrometer (0 – 25 mm))
Piston pin O.D.
Service limit: 13.980 mm (0.5504 in)
(A)
I649G1140265-03
(B)
I837H1140185-01
(A)
(B)
I649G1140267-03
(C)
I649G1140268-03

Suzuki GSX-R600 Specifications

General

Engine Type	4-stroke, liquid-cooled, DOHC
Bore x Stroke	67.0 mm x 42.5 mm
Compression Ratio	12.9:1
Fuel System	Fuel injection
Starter	Electric
Final Drive	Chain
Front Suspension	Inverted telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Engine Displacement	599cc
Transmission	6-speed, constant mesh
Front Tire Size	120/70ZR17M/C (58W)
Rear Tire Size	180/55ZR17M/C (73W)
Overall Length	2030 mm
Overall Width	710 mm
Seat Height	810 mm
Ground Clearance	130 mm
Curb Weight	187 kg
Fuel Tank Capacity	17.0 L