MOTORCYCLE

ISSUE NO. : M-4-0453

DATE : May 22, 2008
PAGE : 1 OF 6

SUBJECT : CORRECTION OF THE SERVICE MANUAL

APPLICABLE MODEL : GSX-R600K8, GSX-R750K8
EFFECTIVE ENGINE OR FRAME NO. :
REFERENCE : E-02, 03, 19, 24, 28, 33

This bulletin is to inform you of the correction of the service manual for the above models.
Please correct the following service manuals according to the following instructions and circulate this
information to your dealers.
GSX-R600 SERVICE MANUAL (BOOK): 99500-35110-01E (Page: 1D-28, 1D-32, 1D-41, 1D-58
and 1D-59)
99500-35110-01F (Page: 1D-29, 1D-34, 1D-43, 1D-60
and 1D-61)
99500-35110-01G (Page: 1D-31, 1D-35, 1D-44, 1D-62
and 1D-63)
99500-35110-03E (Page: 1D-28, 1D-32, 1D-41, 1D-58
and 1D-59)

GSX-R600 SERVICE MANUAL (CD-ROM): 99560-35110-01E

GSX-R750 SERVICE MANUAL (BOOK):
99500-37140-01E (Page: 1D-28, 1D-32, 1D-41, 1D-58
and 1D-59)
99500-37140-01F (Page: 1D-29, 1D-34, 1D-43, 1D-61
and 1D-62)
99500-37140-01G (Page: 1D-30, 1D-34, 1D-44, 1D-62,
1D-63)
99500-37140-03E (Page: 1D-28, 1D-32, 1D-41, 1D-58
and 1D-59)

GSX-R750 SERVICE MANUAL (CD-ROM): 99560-37140-01E

 MOTORCYCLE
ISSUE NO. : M-4-0453
DATE : May 22, 2008
PAGE : 2 OF 6

1D-28 Engine Mechanical:

• Tighten the cylinder head bolts (M10) to the specified Camshaft

torque with a torque wrench sequentially and • The cam shafts are identified by the embossed letters.
diagonally. IN: Intake camshaft
• Additionally tighten the cylinder head bolts with the EX: Exhaust camshaft molybdenum
specified angles diagonally using an angular torque • Before placing the camshafts on the cylinder head,
gauge. apply engine oil to their journals and cam faces.
Tightening torque M/O: Molybdenum oil (MOLYBDENUM OIL
Cylinder head bolt (M10): 31 N m (3.1 kgf-m, 22.5 SOLUTION)
lb-ft) then turn in 1/6 (60 ) turn

I837H1140310-01
I837H1140213-02
• Turn the crankshaft clockwise with the box wrench
• After firmly tightening the cylinder head bolts (M10), and align the line “A” on the CKP sensor rotor to the
install the cylinder head bolts (M6) (3). rib “B” behind the clutch cover while keeping the cam
Tightening torque chain pulled upward.
Cylinder head bolt (M6) (a): 10 N·m (1.0 kgf-m, 7.0
! CAUTION
lb-ft)
• Pull the cam chain upward, or the chain
will be caught between crankcase and cam
drive sprocket.
• To adjust the camshaft timing correctly, be
sure to align the line “A” with rib “B” and
3 (a)
hold this position when installing the
camshafts.

I837H1140214-01

• Install the O-rings (4) and apply engine oil to it.

! CAUTION
Use the new O-rings (4) to prevent oil
leakage.

I837H1140217-01
4

I837H1140215-01
 MOTORCYCLE
ISSUE NO. : M-4-0453
DATE : May 22, 2008
PAGE : 3 OF 6

1D-32 Engine Mechanical:

• Rotate the crankshaft (some turns) and recheck the NOTE

valve timing.
! CAUTION
• Make sure that the adjuster works properly
by checking no slack at point “C”.
• Do not turn the adjuster body until the
outer circlip “A” exceeds the groove “B”.
If the inner circlip “C” is caught in the
groove “B”, plunger may not go out
automatically from the adjuster body even
if pushing force is applied on the head.
In such case, it needs to be disassembled.
Delete
The cam chain tension adjuster can be
serviced with the engine installed in the
frame.
• Tighten the cam chain tension adjuster service cap (6)
to the specified torque.
! CAUTION
Use a new gasket to prevent oil leakage.
Tightening torque
Cam chain tension adjuster service cap (b): 23
N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the valve timing inspection cap (7) to the
specified torque.

! CAUTION
Use a new O-ring to prevent oil leakage.

Tightening torque
“A” 5
Valve timing inspection cap (c): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)

I837H1140275-03

6 (b)

“A”

7 (c)

I837H1140233-03

Cylinder Head Cover

• Check and adjust the valve clearance. Refer to “Valve
5 Clearance Inspection and Adjustment in Section 0B
I837H1140308-02
(Page 0B-4)”.
• Pour engine oil in each oil pocket in the cylinder head.
“C”

I837H1140234-01

I837H1140232-07
 MOTORCYCLE
ISSUE NO. : M-4-0453
DATE : May 22, 2008
PAGE : 4 OF 6

molybdenum Engine Mechanical: 1D-41

• Apply engine oil to the oil seal (8), and press-fit it into • Put on the valve spring retainer (9), and using the
the position. special tools, press down the spring, fit the cotter
halves to the stem end, and release the lifter to allow
! CAUTION the cotter halves to wedge in between retainer and
Do not reuse the removed oil seal. stem.

! CAUTION
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION) • Be sure to restore each spring and valve to
their original positions.
• Be careful not to damage the valve and
valve stem when handling them.
8 • Be careful not to damage the tappet sliding
7 surface with the special tool.

Special tool
(A): 09916–14510 (Valve spring compressor)
(B): 09916–14522 (Valve spring compressor
attachment)
(C): 09919–28620 (Sleeve protector)
I837H1140312-01 : 09916–84511 (Tweezers)
• Insert the valve, with its stem coated with
molybdenum oil solution all around and along the full
stem length without any break.
(A) 9
! CAUTION (C)

When inserting the valve, take care not to

damage the lip of the oil seal.
(B)
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION)

I837H1140056-01

• Be sure that the rounded lip “F” of the cotter fits snugly
into the groove “G” in the stem end.

“G” “F”
9

I705H1140165-01

• Install the valve spring with the small-pitch portion “B” 10

facing cylinder head.

“E”

I837H1140057-01
“D” “C”
9. Valve spring retainer 10. Cotter

“B” • Install the other valves and springs in the same

manner as described previously.
I837H1140055-01

“B”: Small-pitch portion “D”: Upward

“C”: Large-pitch portion “E”: Paint
 MOTORCYCLE
ISSUE NO. : M-4-0453
DATE : May 22, 2008
PAGE : 5 OF 6

1D-58 Engine Mechanical: molybdenum

Crankshaft molybdenum 4) Apply engine oil solution to each crank pin and
1) Apply engine oil to each crank pin bearing surface bearing surface.
and crankshaft journal bearing surface.
! CAUTION
M/O: Molybdenum oil (MOLYBDENUM OIL
Be sure to clean the conrod big end.
SOLUTION)
M/O: Molybdenum oil (MOLYBDENUM OIL
SOLUTION)

I837H1140313-01

2) Position the No. 2 and No. 3 conrod big ends on the

same side, and the No. 1 and No. 4 conrod big ends
I837H1140314-01
on the opposite side of No. 2 and No. 3.
5) When fitting the conrod cap, make sure that I.D.
code “A” on each conrod faces intake side.
6) Apply engine oil to the conrod cap bolts.

“A”

I837H1140110-01

3) Set the crankshaft to the conrods and upper

crankcase.
I837H1140113-01

I837H1140111-01
 MOTORCYCLE
ISSUE NO. : M-4-0453
DATE : May 22, 2008
PAGE : 6 OF 6

Engine Mechanical: 1D-59

7) Tighten the conrod cap bolt by using a 10 mm, 12
point socket wrench in the following two steps.
Tightening torque
Conrod cap bolt: 15 N m (1.5 kgf-m, 11.0 lb-ft)
then turn in 1/4 (90 ) turn
11) Insert the right and left-thrust bearings with the oil
grooves “A” facing towards the crankshaft web.
NOTE
• Right-thrust bearing has green painting.
• Inspect and select the crankshaft thrust
clearance if necessary. Refer to
“Crankshaft Thrust Clearance Inspection
and Selection (Page 1D-79)”.

I837H1140114-01

“A” “A”
I837H1140137-02

Transmission
“a”
Install the transmission. Refer to “Transmission
Installation in Section 5B (Page 5B-5)”.

I837H1140134-01

“a”: 90
molybdenum
8) Apply engine oil to the conrod big end side surfaces.
9) Check the conrod movement for smooth turning.
10) Apply engine oil to each crankshaft journal and
bearing lightly.
M/O: Molybdenum oil (MOLYBDENUM OIL
I837H1140138-01
SOLUTION)

I837H1140139-01
I837H1140315-01