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general information - Martin Nez

general information - Martin Nez

general information - Martin

GSR60099500-36160-01E

  • Page 2 and 3: FOREWORDThis manual contains an int
  • Page 5 and 6: ABBREVIATIONS USED IN THISMANUALABA
  • Page 7 and 8: WIRE COLORB : Black G : Green P : P
  • Page 10 and 11: GENERAL INFORMATION 1-3* If parts r
  • Page 12 and 13: GENERAL INFORMATION 1-5FUEL, OIL AN
  • Page 14 and 15: GENERAL INFORMATION 1-7BREAK-IN PRO
  • Page 16 and 17: GENERAL INFORMATION 1-9SPECIFICATIO
  • Page 18 and 19: PERIODIC MAINTENANCE 2-1PERIODIC MA
  • Page 20 and 21: PERIODIC MAINTENANCE 2-3LUBRICATION
  • Page 22 and 23: PERIODIC MAINTENANCE 2-5SPARK PLUGI
  • Page 24 and 25: PERIODIC MAINTENANCE 2-7VALVE CLEAR
  • Page 26 and 27: PERIODIC MAINTENANCE 2-9• Turn th
  • Page 28 and 29: PERIODIC MAINTENANCE 2-11(INTAKE SI
  • Page 30 and 31: PERIODIC MAINTENANCE 2-13ENGINE OIL
  • Page 32 and 33: PERIODIC MAINTENANCE 2-15ENGINE IDL
  • Page 34 and 35: PERIODIC MAINTENANCE 2-17COOLING SY
  • Page 36 and 37: PERIODIC MAINTENANCE 2-19DRIVE CHAI
  • Page 38 and 39: PERIODIC MAINTENANCE 2-21CLEANING A
  • Page 40 and 41: PERIODIC MAINTENANCE 2-23BRAKE PADS
  • Page 42 and 43: PERIODIC MAINTENANCE 2-25FRONT BRAK
  • Page 44 and 45: PERIODIC MAINTENANCE 2-27FRONT FORK
  • Page 46 and 47: PERIODIC MAINTENANCE 2-29CHASSIS BO
  • Page 48 and 49: PERIODIC MAINTENANCE 2-31COMPRESSIO
  • Page 50 and 51: PERIODIC MAINTENANCE 2-33SDS CHECKU
  • Page 52 and 53:

    PERIODIC MAINTENANCE 2-35Data of in

  • Page 54 and 55:

    3-2 ENGINEENGINE COMPONENTS REMOVAB

  • Page 56 and 57:

    3-4 ENGINERADIATOR• Disconnect th

  • Page 58 and 59:

    3-6 ENGINE• Disconnect the starte

  • Page 60 and 61:

    3-8 ENGINE• Remove the engine spr

  • Page 62 and 63:

    3-10 ENGINE• Tighten the engine m

  • Page 64 and 65:

    3-12 ENGINE• Install the engine s

  • Page 66 and 67:

    3-14 ENGINEENGINE DISASSEMBLYIdenti

  • Page 68 and 69:

    3-16 ENGINE• Remove the intake ca

  • Page 70 and 71:

    3-18 ENGINE• Remove the clutch pu

  • Page 72 and 73:

    3-20 ENGINE• Remove the gearshift

  • Page 74 and 75:

    3-22 ENGINEGENERATOR COVER• Remov

  • Page 76 and 77:

    3-24 ENGINEOIL PRESSURE REGULATOR

  • Page 78 and 79:

    3-26 ENGINE• Remove the piston pi

  • Page 80 and 81:

    3-28 ENGINEINSPECTION• Inspect th

  • Page 82 and 83:

    3-30 ENGINE• If the camshaft jour

  • Page 84 and 85:

    3-32 ENGINE• Install the special

  • Page 86 and 87:

    3-34 ENGINEVALVE STEM DEFLECTION•

  • Page 88 and 89:

    3-36 ENGINE• If the seat width W

  • Page 90 and 91:

    3-38 ENGINE• Install the valve sp

  • Page 92 and 93:

    3-40 ENGINECLUTCHCLUTCH DRIVE PLATE

  • Page 94 and 95:

    3-42 ENGINE• If a large resistanc

  • Page 96 and 97:

    3-44 ENGINEOIL PRESSURE REGULATOR

  • Page 98 and 99:

    3-46 ENGINEREASSEMBLYAssemble the c

  • Page 100 and 101:

    3-48 ENGINECYLINDERCRANKCASE SERVIC

  • Page 102 and 103:

    3-50 ENGINEPISTON RING-TO-GROOVE CL

  • Page 104 and 105:

    3-52 ENGINEGEARSHIFT FORK THICKNESS

  • Page 106 and 107:

    3-54 ENGINE• Install the gearshif

  • Page 108 and 109:

    3-56 ENGINEInstallation• Fit new

  • Page 110 and 111:

    3-58 ENGINECRANKSHAFT AND CONRODCRA

  • Page 112 and 113:

    3-60 ENGINE• Remove the bearing c

  • Page 114 and 115:

    3-62 ENGINECRANKSHAFT JOURNAL BEARI

  • Page 116 and 117:

    3-64 ENGINE Crankshaft journal O.D.

  • Page 118 and 119:

    3-66 ENGINE Thrust bearing selectio

  • Page 120 and 121:

    3-68 ENGINE•1st ring 5 and 2nd ri

  • Page 122 and 123:

    3-70 ENGINE• Set the crankshaft t

  • Page 124 and 125:

    3-72 ENGINE• Apply SUZUKI BOND to

  • Page 126 and 127:

    3-74 ENGINETRANSMISSION• Install

  • Page 128 and 129:

    3-76 ENGINE• Tighten the crankcas

  • Page 130 and 131:

    3-78 ENGINEOIL PAN• Apply SUZUKI

  • Page 132 and 133:

    3-80 ENGINE• Tighten the water pu

  • Page 134 and 135:

    3-82 ENGINEGENERATOR COVER• Apply

  • Page 136 and 137:

    3-84 ENGINESTARTER CLUTCH• Instal

  • Page 138 and 139:

    3-86 ENGINENOTE:Hook the return spr

  • Page 140 and 141:

    3-88 ENGINE• Install the oil pump

  • Page 142 and 143:

    3-90 ENGINE• Insert the clutch dr

  • Page 144 and 145:

    3-92 ENGINECYLINDER HEAD• Fit the

  • Page 146 and 147:

    3-94 ENGINEPull the cam chain upwar

  • Page 148 and 149:

    3-96 ENGINE• Install the dowel pi

  • Page 150 and 151:

    3-98 ENGINE• Install the gasket 4

  • Page 152 and 153:

    3-100 ENGINE• Tighten the valve t

  • Page 154 and 155:

    FI SYSTEM DIAGNOSIS 4-1FI SYSTEM DI

  • Page 156 and 157:

    FI SYSTEM DIAGNOSIS 4-3PRECAUTIONS

  • Page 158 and 159:

    FI SYSTEM DIAGNOSIS 4-5• When dis

  • Page 160 and 161:

    FI SYSTEM DIAGNOSIS 4-7Continuity c

  • Page 162 and 163:

    FI SYSTEM DIAGNOSIS 4-9USING THE MU

  • Page 164 and 165:

    FI SYSTEM DIAGNOSIS 4-11COMPENSATIO

  • Page 166 and 167:

    FI SYSTEM DIAGNOSIS 4-13ECMJ Second

  • Page 168 and 169:

    FI SYSTEM DIAGNOSIS 4-15ECM TERMINA

  • Page 170 and 171:

    FI SYSTEM DIAGNOSIS 4-17DEALER MODE

  • Page 172 and 173:

    FI SYSTEM DIAGNOSIS 4-19TPS ADJUSTM

  • Page 174 and 175:

    FI SYSTEM DIAGNOSIS 4-21ITEMFAIL-SA

  • Page 176 and 177:

    FI SYSTEM DIAGNOSIS 4-23MOTORCYCLE/

  • Page 178 and 179:

    FI SYSTEM DIAGNOSIS 4-25USE OF SDS

  • Page 180 and 181:

    FI SYSTEM DIAGNOSIS 4-27SHOW DATA W

  • Page 182 and 183:

    FI SYSTEM DIAGNOSIS 4-29DTC No.C21P

  • Page 184 and 185:

    FI SYSTEM DIAGNOSIS 4-31DTC No.C44P

  • Page 186 and 187:

    FI SYSTEM DIAGNOSIS 4-33Step 21) Cr

  • Page 188 and 189:

    FI SYSTEM DIAGNOSIS 4-355) If OK, t

  • Page 190 and 191:

    FI SYSTEM DIAGNOSIS 4-374) Disconne

  • Page 192 and 193:

    FI SYSTEM DIAGNOSIS 4-397) Disconne

  • Page 194 and 195:

    FI SYSTEM DIAGNOSIS 4-41Output volt

  • Page 196 and 197:

    FI SYSTEM DIAGNOSIS 4-43 TP sensor

  • Page 198 and 199:

    FI SYSTEM DIAGNOSIS 4-45Step 21) Tu

  • Page 200 and 201:

    FI SYSTEM DIAGNOSIS 4-47“C15” (

  • Page 202 and 203:

    FI SYSTEM DIAGNOSIS 4-49Step 1 (Whe

  • Page 204 and 205:

    FI SYSTEM DIAGNOSIS 4-51“C21” (

  • Page 206 and 207:

    FI SYSTEM DIAGNOSIS 4-53Step 1 (Whe

  • Page 208 and 209:

    FI SYSTEM DIAGNOSIS 4-55“C22” (

  • Page 210 and 211:

    FI SYSTEM DIAGNOSIS 4-576) Disconne

  • Page 212 and 213:

    FI SYSTEM DIAGNOSIS 4-59Step 31) Re

  • Page 214 and 215:

    FI SYSTEM DIAGNOSIS 4-61Step 1 (Whe

  • Page 216 and 217:

    FI SYSTEM DIAGNOSIS 4-63Step 21) Co

  • Page 218 and 219:

    FI SYSTEM DIAGNOSIS 4-65Step 21) Tu

  • Page 220 and 221:

    FI SYSTEM DIAGNOSIS 4-67“C29” (

  • Page 222 and 223:

    FI SYSTEM DIAGNOSIS 4-69Step 1 (Whe

  • Page 224 and 225:

    FI SYSTEM DIAGNOSIS 4-718) If OK, t

  • Page 226 and 227:

    FI SYSTEM DIAGNOSIS 4-73Is the volt

  • Page 228 and 229:

    FI SYSTEM DIAGNOSIS 4-755) If OK, t

  • Page 230 and 231:

    FI SYSTEM DIAGNOSIS 4-77Step 1 (Whe

  • Page 232 and 233:

    FI SYSTEM DIAGNOSIS 4-79“C44” (

  • Page 234 and 235:

    FI SYSTEM DIAGNOSIS 4-81Is the volt

  • Page 236 and 237:

    FI SYSTEM DIAGNOSIS 4-83“C49” (

  • Page 238 and 239:

    FI SYSTEM DIAGNOSIS 4-85“C60” (

  • Page 240 and 241:

    FI SYSTEM DIAGNOSIS 4-87SENSORSCMP

  • Page 242 and 243:

    FI SYSTEM DIAGNOSIS 4-89TO SENSOR I

  • Page 244 and 245:

    FUEL SYSTEM AND THROTTLE BODY 5-1FU

  • Page 246 and 247:

    FUEL SYSTEM AND THROTTLE BODY 5-3FU

  • Page 248 and 249:

    FUEL SYSTEM AND THROTTLE BODY 5-5FU

  • Page 250 and 251:

    FUEL SYSTEM AND THROTTLE BODY 5-7FU

  • Page 252 and 253:

    FUEL SYSTEM AND THROTTLE BODY 5-9

  • Page 254 and 255:

    FUEL SYSTEM AND THROTTLE BODY 5-11

  • Page 256 and 257:

    FUEL SYSTEM AND THROTTLE BODY 5-13A

  • Page 259 and 260:

    5-16 FUEL SYSTEM AND THROTTLE BODYT

  • Page 261 and 262:

    5-18 FUEL SYSTEM AND THROTTLE BODY

  • Page 263 and 264:

    5-20 FUEL SYSTEM AND THROTTLE BODYA

  • Page 265 and 266:

    5-22 FUEL SYSTEM AND THROTTLE BODYF

  • Page 267 and 268:

    5-24 FUEL SYSTEM AND THROTTLE BODYT

  • Page 269 and 270:

    EXHAUST SYSTEM 6-1EXHAUST SYSTEMCON

  • Page 271 and 272:

    EXHAUST SYSTEM 6-3REMOVAL• Remove

  • Page 273 and 274:

    EXHAUST SYSTEM 6-5INSTALLATIONInsta

  • Page 275 and 276:

    7-2 COOLING AND LUBRICATION SYSTEME

  • Page 277 and 278:

    7-4 COOLING AND LUBRICATION SYSTEMR

  • Page 279 and 280:

    7-6 COOLING AND LUBRICATION SYSTEMC

  • Page 281 and 282:

    7-8 COOLING AND LUBRICATION SYSTEMI

  • Page 283 and 284:

    7-10 COOLING AND LUBRICATION SYSTEM

  • Page 285 and 286:

    7-12 COOLING AND LUBRICATION SYSTEM

  • Page 287 and 288:

    7-14 COOLING AND LUBRICATION SYSTEM

  • Page 289 and 290:

    7-16 COOLING AND LUBRICATION SYSTEM

  • Page 291 and 292:

    7-18 COOLING AND LUBRICATION SYSTEM

  • Page 293 and 294:

    7-20 COOLING AND LUBRICATION SYSTEM

  • Page 295 and 296:

    CHASSIS 8-1CHASSISCONTENTSEXTERIOR

  • Page 297 and 298:

    CHASSIS 8-3EXTERIOR PARTSREMOVALSEA

  • Page 299 and 300:

    CHASSIS 8-5MUFFLER COVER• Remove

  • Page 301 and 302:

    CHASSIS 8-7REMOVAL• Remove the br

  • Page 303 and 304:

    CHASSIS 8-9WHEEL BEARINGInspect the

  • Page 305 and 306:

    CHASSIS 8-11• Install the wheel b

  • Page 307 and 308:

    CHASSIS 8-13FRONT FORKCONSTRUCTION1

  • Page 309 and 310:

    CHASSIS 8-15• Remove the protecto

  • Page 311 and 312:

    CHASSIS 8-17CYLINDER RINGInspect th

  • Page 313 and 314:

    CHASSIS 8-19FRONT FORK PROTECTOR•

  • Page 315 and 316:

    CHASSIS 8-21STEERINGCONSTRUCTION1 S

  • Page 317 and 318:

    CHASSIS 8-23• Remove the steering

  • Page 319 and 320:

    CHASSIS 8-25• Turn the steering s

  • Page 321 and 322:

    CHASSIS 8-27HANDLEBARSCONSTRUCTION1

  • Page 323 and 324:

    CHASSIS 8-29• Set the handlebars

  • Page 325 and 326:

    CHASSIS 8-31REAR WHEELCONSTRUCTION1

  • Page 327 and 328:

    CHASSIS 8-33INSPECTION AND DISASSEM

  • Page 329 and 330:

    CHASSIS 8-35REASSEMBLY AND INSTALLA

  • Page 331 and 332:

    CHASSIS 8-37DUST SEALS• Install n

  • Page 333 and 334:

    CHASSIS 8-39REAR SHOCK ABSORBERCONS

  • Page 335 and 336:

    CHASSIS 8-41REAR SHOCK ABSORBER DIS

  • Page 337 and 338:

    CHASSIS 8-43REAR SUSPENSIONCONSTRUC

  • Page 339 and 340:

    CHASSIS 8-45• Remove the cushion

  • Page 341 and 342:

    CHASSIS 8-47CUSHION LEVER BEARINGIn

  • Page 343 and 344:

    CHASSIS 8-49REASSEMBLYReassemble th

  • Page 345 and 346:

    CHASSIS 8-51• Assemble the cushio

  • Page 347 and 348:

    CHASSIS 8-53FRONT BRAKECONSTRUCTION

  • Page 349 and 350:

    CHASSIS 8-55• Install new brake p

  • Page 351 and 352:

    CHASSIS 8-57• Remove the dust sea

  • Page 353 and 354:

    CHASSIS 8-59CALIPER INSTALLATIONIns

  • Page 355 and 356:

    CHASSIS 8-61• Pull out the dust b

  • Page 357 and 358:

    CHASSIS 8-63• When installing the

  • Page 359 and 360:

    CHASSIS 8-65* This brake system is

  • Page 361 and 362:

    CHASSIS 8-67CALIPER REMOVAL AND DIS

  • Page 363 and 364:

    CHASSIS 8-69• Tighten the brake c

  • Page 365 and 366:

    CHASSIS 8-71MASTER CYLINDER INSPECT

  • Page 367 and 368:

    CHASSIS 8-73TIRE AND WHEELTIRE REMO

  • Page 369 and 370:

    CHASSIS 8-75TIRE INSTALLATION• Ap

  • Page 371 and 372:

    CHASSIS 8-77DRIVE CHAINUse the spec

  • Page 373 and 374:

    CHASSIS 8-79• Apply grease on the

  • Page 375 and 376:

    ELECTRICAL SYSTEM 9-1ELECTRICAL SYS

  • Page 377 and 378:

    ELECTRICAL SYSTEM 9-3CAUTIONS IN SE

  • Page 379 and 380:

    ELECTRICAL SYSTEM 9-5USING THE MULT

  • Page 381 and 382:

    ELECTRICAL SYSTEM 9-71 CMP sensor (

  • Page 383 and 384:

    ELECTRICAL SYSTEM 9-9Step 51) Measu

  • Page 385 and 386:

    ELECTRICAL SYSTEM 9-11GENERATOR NO-

  • Page 387 and 388:

    ELECTRICAL SYSTEM 9-13Step 31) Meas

  • Page 389 and 390:

    ELECTRICAL SYSTEM 9-15COMMUTATORIns

  • Page 391 and 392:

    ELECTRICAL SYSTEM 9-17Measure the r

  • Page 393 and 394:

    ELECTRICAL SYSTEM 9-19TURN SIGNAL/S

  • Page 395 and 396:

    ELECTRICAL SYSTEM 9-21IMMOBILIZERDE

  • Page 397 and 398:

    ELECTRICAL SYSTEM 9-23TROUBLESHOOTI

  • Page 399 and 400:

    ELECTRICAL SYSTEM 9-25INSPECTIONIGN

  • Page 401 and 402:

    ELECTRICAL SYSTEM 9-27CKP SENSOR PE

  • Page 403 and 404:

    ELECTRICAL SYSTEM 9-29COMBINATION M

  • Page 405 and 406:

    ELECTRICAL SYSTEM 9-31INSPECTIONLED

  • Page 407 and 408:

    ELECTRICAL SYSTEM 9-33FUEL LEVEL GA

  • Page 409 and 410:

    ELECTRICAL SYSTEM 9-35LAMPSHEADLIGH

  • Page 411 and 412:

    ELECTRICAL SYSTEM 9-37RELAYSTURN SI

  • Page 413 and 414:

    ELECTRICAL SYSTEM 9-39SWITCHES INSP

  • Page 415 and 416:

    ELECTRICAL SYSTEM 9-41NOTE:If no ai

  • Page 417 and 418:

    SERVICING INFORMATIONSERVICING INFO

  • Page 419 and 420:

    SERVICING INFORMATION 10-3DTC No.C2

  • Page 421 and 422:

    SERVICING INFORMATION 10-5DTC No.C4

  • Page 423 and 424:

    SERVICING INFORMATION 10-7Complaint

  • Page 425 and 426:

    SERVICING INFORMATION 10-9Complaint

  • Page 427 and 428:

    SERVICING INFORMATION 10-11Complain

  • Page 429 and 430:

    SERVICING INFORMATION 10-13CHASSISC

  • Page 431 and 432:

    SERVICING INFORMATION 10-15ELECTRIC

  • Page 433 and 434:

    SERVICING INFORMATION 10-17WIRING H

  • Page 435 and 436:

    SERVICING INFORMATION 10-19*2*36 N

  • Page 437 and 438:

    SERVICING INFORMATION 10-21THROTTLE

  • Page 439 and 440:

    SERVICING INFORMATION 10-23COOLING

  • Page 441 and 442:

    SERVICING INFORMATION 10-25REAR BRA

  • Page 443 and 444:

    SERVICING INFORMATION 10-27FRAME CO

  • Page 445 and 446:

    SERVICING INFORMATION 10-29REAR FEN

  • Page 447 and 448:

    SERVICING INFORMATION 10-31PILLION

  • Page 449 and 450:

    SERVICING INFORMATION 10-33SPECIAL

  • Page 451 and 452:

    SERVICING INFORMATION 10-3509920-34

  • Page 453 and 454:

    SERVICING INFORMATION 10-37TIGHTENI

  • Page 455 and 456:

    SERVICING INFORMATION 10-39CHASSISI

  • Page 457 and 458:

    SERVICING INFORMATION 10-41SERVICE

  • Page 459 and 460:

    SERVICING INFORMATION 10-43OIL PUMP

  • Page 461 and 462:

    SERVICING INFORMATION 10-45FI SENSO

  • Page 463 and 464:

    SERVICING INFORMATION 10-47WATTAGEI

  • Page 465 and 466:

    SERVICING INFORMATION 10-49FUEL + O

  • Page 467 and 468:

    11-2 EMISSION CONTROL INFORMATIONEM

  • Page 469 and 470:

    11-4 EMISSION CONTROL INFORMATIONEX

  • Page 471 and 472:

    11-6 EMISSION CONTROL INFORMATIONPA

  • Page 473 and 474:

    11-8 EMISSION CONTROL INFORMATIONPA

  • Page 475 and 476:

    WIRING DIAGRAME-02, 19, 24Wiring di

  • Page 477:

    Printed in JapanK6

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