The Suzuki GSX-R600 is a popular sport bike that has dominated the 600cc class since its debut in 1992.
With its lightweight, agile, and powerful performance, the GSX-R600 is a favorite among racers and street riders.
Still, like any other machine, the GSX-R600 can also encounter some problems that can affect its reliability and performance.
This article will cover some of the most common issues with the Suzuki GSX-R600 and its solutions.
Table of Contents
1. Suzuki GSX-R600 Won’t Start
The most common reasons why a Suzuki GSX-R600 won’t start is due to a dead battery, a faulty starter, a bad fuel pump, loose or corroded wires or connections, blown fuses, and faulty sensors and safety switches.
Dead Battery
A dead battery is one of the most common reasons a GSX-R600 won’t start. The battery provides the power to the ignition system, the starter motor, and the fuel pump.
If the battery is weak or drained, it won’t be able to crank the engine or deliver enough voltage to the spark plugs.
To check your GSX-R’s battery, use a multimeter or a voltmeter and measure the voltage across the terminals. A fully charged battery should have at least 12.6 volts. If the voltage exceeds 12 volts, the battery must be recharged or replaced.
Bad Starter
A faulty starter is another possible cause of a no-start condition on the GSX-R600. The starter is an electric motor that turns the engine over when you press the start button.
If the starter is worn out, damaged, or shorted, it won’t be able to spin the engine fast enough.
To test the starter, you can use a jumper wire to bypass the relay and connect the battery’s positive terminal directly to the starter terminal. The starter must be repaired or replaced if it still doesn’t work.
Faulty Fuel Pump
A bad fuel pump can also prevent the GSX-R600 from starting. The fuel pump is responsible for delivering fuel from the tank to the injectors under high pressure.
If the fuel pump is clogged, faulty, or has low pressure, it won’t be able to supply enough fuel to the engine for combustion.
To check the fuel pump, you can listen for a whirring sound when you turn on the ignition. You can also use a pressure gauge to measure the fuel pressure at the fuel rail. The normal pressure range for the GSX-R600 is 43-49 psi.
Loose or Corroded Wires
Loose or corroded wires can also cause starting problems on the GSX-R600. The wires are part of the electrical system that connects the battery, the ignition switch, the starter relay, and other components.
If any of these wires are loose, broken, or corroded, they can create a poor connection or a short circuit that can affect the power supply or the signal transmission.
To inspect the wires, you can use a visual exam and look for any signs of damage, wear, or corrosion. You can also use a continuity tester to check for any breaks or shorts in the wires.
Blown Fuses
Blown fuses are another common reason why a GSX-R600 won’t start. The fuses are protective devices that prevent excessive current from damaging the electrical components.
A short circuit or an overload in any of these components, such as the ignition coil, the injector, or the fuel pump, can cause a fuse to blow and cut off the power supply.
To check the fuses, you can visually inspect and look for any signs of melting or burning on the fuse body. You can also use a multimeter or a test light to check for continuity across the fuse terminals.
Faulty Switches and Sensors
Faulty switches and sensors can also prevent the GSX-R600 from starting. The switches and sensors are part of the safety system that prevents the bike from starting in unsafe conditions.
Some of the switches and sensors that can cause a no-start condition are:
- Kill Switch: The kill switch is on the right handlebar and can cut off the ignition and fuel injection. Ensure the kill switch is in the ON position and not accidentally flipped to the OFF position. Also, check for loose wiring or a blown fuse affecting the kill switch function.
- Side Stand Switch: The side stand switch is located near the side stand and can detect if the side stand is up or down. If the side stand is down and the bike is in gear, the side stand switch will prevent the bike from starting. Ensure the side stand is up, and the bike is in neutral or clutch before starting. Also, ensure the sensor isn’t damaged, and its wiring is intact.
- Clutch Switch: The clutch switch is located near the clutch lever and can detect if the clutch is engaged or disengaged. If the clutch is engaged and the bike is in gear, the clutch switch will prevent the bike from starting. Make sure the clutch is disengaged before starting. Also, ensure the switch isn’t loose or faulty, and its wiring is connected.
- Tip-over Sensor: The tip-over sensor is located under the seat and can detect if the bike has fallen over or tilted beyond a certain angle. If the tip-over sensor detects a tip-over, it will cut off the fuel pump and ignition to prevent fire or damage. To reset the tip-over sensor, turn off the ignition and then turn it back on after a few seconds.
2. Suzuki GSX-R600 Won’t Stay Running
The most common reasons a Suzuki GSX-R600 won’t stay running are clogged fuel injectors, faulty ignition coils, and vacuum leaks.
The fuel injector sprays fuel into the combustion chamber under high pressure and precise timing.
If the fuel injector is dirty, blocked, or faulty, it won’t be able to deliver enough fuel to the engine for proper combustion. This can result in poor performance, rough idle, stalling, or no-start conditions.
To clean the fuel injector, you can use an OEM-recommended fuel injector cleaner and follow the instructions on the label.
The ignition coil transforms the battery voltage into a high-voltage spark that ignites the fuel-air mixture in the cylinder.
If the ignition coil is worn out, damaged, or shorted, it won’t be able to produce a strong enough spark or no spark at all. This can result in misfires, loss of power, backfires, or engine shutdown.
To test the ignition coil, you can use a spark tester and check for a bright blue spark at each spark plug.
A vacuum leak is an unwanted opening in the intake system that allows air to enter the engine without passing through the throttle body or the mass air flow sensor. This can cause a lean condition, with too much air and insufficient fuel in the combustion chamber. This can result in poor idle quality, hesitation, surging, or stalling.
To check for a vacuum leak, you can use a visual inspection and look for any cracks, holes, or loose connections in the intake hoses and pipes. You can also use a spray bottle of water or carb cleaner and spray around the intake manifold and listen for any changes in the engine sound.
Related: 7 Common Suzuki GSX R600 Problems (Explained)
3. Suzuki GSX-R600 Won’t Crank
A faulty starter relay, crank position sensor, or ignition switch can cause your Suzuki GSX-R600 not to crank.
The starter relay sends power to the starter motor when you press the start button. If the starter relay is damaged, corroded, or has a bad connection, it won’t be able to activate the starter motor.
To check the starter relay, you can use a multimeter and measure the resistance across the terminals. It should be between 3 and 5 ohms. You can also use a jumper wire to bypass the relay and connect the battery directly to the starter motor. If the starter motor works, then the relay is faulty.
The crank position sensor is responsible for detecting the position and speed of the crankshaft and sending a signal to the ECU. The ECU uses this signal to control the ignition timing and fuel injection.
If the crank position sensor is faulty, overheated, or has a bad connection, it won’t be able to send a proper signal to the ECU. This can result in no spark or fuel delivery to the engine. You can use a multimeter to measure the resistance across the terminals to check the crank position sensor. It should be between 150 and 250 ohms.
The ignition switch is responsible for turning on the electrical system when you insert and turn the key. If the ignition switch is worn out, damaged, or has a bad connection, it won’t be able to supply power to the starter relay, the fuel pump, and other components.
You can use a multimeter to measure the voltage across the terminals when you turn the key to check the ignition switch. It should be equal to the battery voltage. You can also use a test light and check for power at each terminal when you turn the key.
4. Suzuki GSX-R600 Won’t Start When Hot
The Suzuki GSX-R600 most commonly has starting problems when it’s hot due to a faulty crank position sensor, a weak battery, or a faulty starter motor.
The crank position sensor is responsible for detecting the position and speed of the crankshaft and sending a signal to the ECU. The ECU uses this signal to control the ignition timing and fuel injection.
If the crank position sensor is faulty, overheated, or has a bad connection, it won’t be able to send a proper signal to the ECU. This can result in no spark or fuel delivery to the engine.
The battery provides the power to the starter motor, the ignition system, and the fuel pump.
A hot engine has more compression and requires more power to start than a cold engine; if the battery is weak or drained, it won’t be able to crank the engine or deliver enough voltage to the spark plugs.
The starter motor is an electric motor that turns your Gixxer’s engine over when you press the start button. If the starter motor is worn out, damaged, or shorted, it won’t be able to spin the engine fast enough.
A hot starter motor can also have more resistance and draw more current than a cold starter motor, resulting in a slow or no crank condition.
To test the starter motor, you can use a jumper wire to bypass the relay and connect the battery’s positive terminal directly to the starter terminal. If the starter motor still doesn’t work, it must be repaired or replaced.
5. Suzuki GSX-R600 Won’t Go Into Neutral
A misadjusted clutch, worn gear dogs, or a bent shift fork can all cause the Suzuki GSX-R600 to not go into neutral.
The clutch is responsible for disengaging the engine from the transmission when you pull the clutch lever. If the clutch is too tight or too loose, it won’t be able to fully disengage or engage the gears, leading to difficulty shifting, grinding noises, or false neutrals.
To adjust the clutch, you can use the adjuster knob on the clutch lever or the adjuster nut on the engine side. You should have about 10-15 mm free play at the lever.
The gear dogs are part of the transmission that lock and unlock the gears when you shift. If the gear dogs are worn out, rounded, or chipped, they won’t be able to engage or disengage the gears smoothly. This can result in hard shifting, jumping out of gear, or getting stuck in gear.
The shift fork is part of your Gixxer’s transmission that moves the gears along the shift drum when you shift. If the shift fork is bent, twisted, or broken, it won’t be able to align the gears properly. This can result in missed shifts, false neutrals, or no neutrals.
6. Suzuki GSX-R600 Won’t Rev Up
A clogged high-pressure fuel filter, faulty throttle position sensor, or malfunctioning exhaust valve can cause your Suzuki GSX-R600 not to rev up.
The high-pressure fuel filter is responsible for filtering the fuel before it reaches the injectors. If the high-pressure fuel filter is dirty, blocked, or damaged, it won’t be able to deliver enough fuel to the engine for proper combustion. This can result in poor performance, hesitation, surging, or bogging down.
The exhaust valve controls the exhaust flow and back pressure according to the engine speed and load. If the exhaust valve is stuck, damaged, or has a bad connection, it won’t be able to adjust the exhaust flow properly. This can result in loss of power, backfiring, or engine shutdown.
7. Suzuki GSX-R600 Won’t Go Into Gear
A bent shift fork, worn clutch plates, and a faulty gear position sensor are the most common culprits that prevent the GSX-R600 from going into gear.
Suppose the gear position sensor is faulty, dirty, or has a bad connection. In that case, it won’t be able to send a proper signal to the ECU and the neutral light, resulting in difficulty shifting and false neutrals.
If the shift fork is bent, twisted, or broken, it won’t be able to align the gears properly, leading to missed shifts, false neutrals, and your GSX-R not going into gear or getting stuck in gear.
The clutch plates are part of the clutch that engage and disengage the engine from the transmission when you pull and release the clutch lever. If the clutch plates are worn out, glazed, or warped, they won’t be able to grip or release the gears smoothly. This can result in hard shifting, gear slipping, or dragging.
8. Suzuki GSX-R600 Not Idling
A dirty idle speed control valve can cause the GSX-R600 to not idle.
The idle speed control valve regulates the idle speed by controlling the amount of air that bypasses the throttle body. If the idle speed control valve is dirty, clogged, or stuck, it won’t be able to adjust the idle speed properly. This can result in erratic idle, stalling, or no-start conditions.
Also, check your spark plugs and throttle position sensor.
9. Suzuki GSX-R600 Overheating
The most common causes of overheating on a Suzuki GSX-R600 are low coolant levels or a faulty radiator or thermostat.
If the thermostat is stuck closed, it won’t be able to open and allow the coolant to flow to the radiator, resulting in no cooling, high engine temperature, or boiling coolant.
If the radiator fan is damaged, seized, or has a bad connection, it won’t be able to spin or turn on when needed, causing insufficient cooling, especially when the bike is idling or moving slowly.
Related: How Long Does A Suzuki GSX-R600 Last? (Solved & Explained)
10. Suzuki GSX-R600 Leaking Oil
The GSX-R600 can leak oil from various sources, such as the oil filter, oil pan, oil cooler, valve cover, or crankcase. To find the source of the leak, you can use a visual inspection and look for any signs of oil stains, drips, or seepage. You can also use a UV dye and a black light to trace the leak.
11. Suzuki GSX-R600 Losing Power
The GSX-R600 can lose power due to various reasons, such as a clogged air filter, dirty fuel injectors, bad spark plugs, faulty ECU, or low compression. To diagnose the cause of the power loss, you can use a scan tool and check for any error codes. You can also use a multimeter and a compression tester to check the electrical and mechanical components.
