general information - Martin Nez

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3-48 ENGINECYLINDERCRANKCASE SERVICING (3-51)CYLINDER DISTORTION• Check the gasketed surface of the cylinder for distortion witha straightedge and thickness gauge, taking a clearance readingat several places as indicated.• If the largest reading at any position of the straightedgeexceeds the limit, replace the crankcase set. Cylinder distortion:Service Limit: 0.02 mm 09900-20803: Thickness gaugeCYLINDER BORE• Inspect the cylinder wall for any scratches, nicks or otherdamage.• Measure the cylinder bore diameter at six places. Cylinder bore:Standard: 67.000 – 67.015 mm 09900-20508: Cylinder gauge set
ENGINE 3-49PISTON AND PISTON RINGPISTON DIAMETER• Using a micrometer, measure the piston outside diameter at15 mm A from the piston skirt end.• If the measurement is less than the limit, replace the piston. Piston diameter:Service Limit: 66.845 mmat 15 mm from the skirt end 09900-20203: Micrometer (50 – 75 mm)PISTON-TO-CYLINDER CLEARANCE• Subtract the piston diameter from the cylinder bore diameter.(3-48)• If the piston-to-cylinder clearance exceeds the service limit,replace the crankcase set or the piston, or both. Piston-to-cylinder clearance:Service Limit: 0.120 mmPISTON PIN AND PIN BORE• Measure the piston pin bore inside diameter using the smallbore gauge.• If the measurement is out of specifications replace the piston. Piston pin bore I.D.:Service Limit: 14.030 mm 09900-20602: Dial gauge (1/1 000 mm)09900-22401: Small bore gauge (10 – 18 mm)• Measure the piston pin outside diameter at three positionsusing the micrometer.• If any of the measurements are out of specification, replacethe piston pin. Piston pin O.D.:Service Limit: 13.980 mm 09900-20205: Micrometer (0 – 25 mm)
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GSR60099500-36160-01E
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HOW TO USE THIS MANUALTO LOCATE WHA
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MMAL-CodeMaxMILMinNNOXOOHCOPSPPCVRS
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GENERAL INFORMATION 1-1GENERAL INFO
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1-4 GENERAL INFORMATIONSUZUKI GSR60
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1-6 GENERAL INFORMATIONENGINE COOLA
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1-8 GENERAL INFORMATIONINFORMATION
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1-10 GENERAL INFORMATIONCHASSISFron
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2-2 PERIODIC MAINTENANCEPERIODIC MA
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2-4 PERIODIC MAINTENANCEMAINTENANCE
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2-6 PERIODIC MAINTENANCESPARK PLUG
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2-8 PERIODIC MAINTENANCE• Remove
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2-10 PERIODIC MAINTENANCENOTE:* Be
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2-12 PERIODIC MAINTENANCE(EXHAUST S
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2-14 PERIODIC MAINTENANCEOIL FILTER
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2-16 PERIODIC MAINTENANCECLUTCHInsp
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2-18 PERIODIC MAINTENANCEAIR BLEEDI
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2-20 PERIODIC MAINTENANCE• Count
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2-22 PERIODIC MAINTENANCEBRAKE(BRAK
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2-24 PERIODIC MAINTENANCEBRAKE LIGH
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2-26 PERIODIC MAINTENANCETIRESInspe
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2-28 PERIODIC MAINTENANCEEXHAUST PI
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2-30 PERIODIC MAINTENANCE
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Page 53 and 54: ENGINE 3-1ENGINECONTENTSENGINE COMP
Page 55 and 56: ENGINE 3-3ENGINE REMOVAL AND INSTAL
Page 57 and 58: ENGINE 3-5• Remove the front engi
Page 59 and 60: ENGINE 3-7ENGINE SPROCKET AND GEAR
Page 61 and 62: ENGINE 3-9• Remove the engine mou
Page 63 and 64: ENGINE 3-11• Tighten all engine m
Page 65 and 66: ENGINE 3-13• Replace the exhaust
Page 67 and 68: ENGINE 3-15CAMSHAFTS• Remove the
Page 69 and 70: ENGINE 3-17CLUTCH• Remove the clu
Page 71 and 72: ENGINE 3-19• Remove the thrust wa
Page 73 and 74: ENGINE 3-21• Remove the starter c
Page 75 and 76: ENGINE 3-23GEAR POSITION SWITCH•
Page 77 and 78: ENGINE 3-25MIDDLE CRANKCASE• Remo
Page 79 and 80: ENGINE 3-27ENGINE COMPONENTS INSPEC
Page 81 and 82: ENGINE 3-29CAMSHAFT JOURNAL WEAR•
Page 83 and 84: ENGINE 3-31CAM CHAIN TENSIONERINSPE
Page 85 and 86: ENGINE 3-33VALVE STEM RUNOUT• Sup
Page 87 and 88: ENGINE 3-35• Cool down the new va
Page 89 and 90: ENGINE 3-37• Clean and assemble t
Page 91 and 92: ENGINE 3-39INTAKE PIPE• Remove th
Page 93 and 94: ENGINE 3-41CLUTCH BEARING INSPECTIO
Page 95 and 96: ENGINE 3-43WATER PUMPDISASSEMBLY/IN
Page 97 and 98: ENGINE 3-45TRANSMISSIONDISASSEMBLYD
Page 99: ENGINE 3-47TRANSMISSION PARTS LOCAT
Page 103 and 104: ENGINE 3-51CRANKCASEGEARSHIFT FORK
Page 105 and 106: ENGINE 3-53• Remove the oil seal
Page 107 and 108: ENGINE 3-55OIL JETRemoval• Remove
Page 109 and 110: ENGINE 3-57• Remove the water jac
Page 111 and 112: ENGINE 3-59CONROD BIG END SIDE CLEA
Page 113 and 114: ENGINE 3-61 Crank pin O.D.CodeO.D.
Page 115 and 116: ENGINE 3-63• Check the correspond
Page 117 and 118: ENGINE 3-65CRANKSHAFT THRUST BEARIN
Page 119 and 120: ENGINE 3-67ENGINE REASSEMBLY• Rea
Page 121 and 122: ENGINE 3-69• Install the pistons
Page 123 and 124: ENGINE 3-71• Insert the right and
Page 125 and 126: ENGINE 3-73• Install the regulato
Page 127 and 128: ENGINE 3-75• Apply SUZUKI BOND to
Page 129 and 130: ENGINE 3-77OIL STRAINER• Install
Page 131 and 132: ENGINE 3-79CRANKCASE BREATHER COVER
Page 133 and 134: ENGINE 3-81• Apply SUZUKI BOND to
Page 135 and 136: ENGINE 3-83CAM CHAIN DRIVE SPROCKET
Page 137 and 138: ENGINE 3-85• Install the starter
Page 139 and 140: ENGINE 3-87OIL PUMP• Install the
Page 141 and 142: ENGINE 3-89• Lock the clutch slee
Page 143 and 144: ENGINE 3-91• Install the pressure
Page 145 and 146: ENGINE 3-93• Apply SUZUKI SUPER G
Page 147 and 148: ENGINE 3-95• Pull the cam chain l
Page 149 and 150: ENGINE 3-97• Tighten the camshaft
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ENGINE 3-99A Cam chain tension adju
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ENGINE 3-101• Tighten the head co
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4-2 FI SYSTEM DIAGNOSISFI SYSTEM DI
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4-4 FI SYSTEM DIAGNOSIS• When con
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4-6 FI SYSTEM DIAGNOSISELECTRICAL C
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4-8 FI SYSTEM DIAGNOSISSHORT CIRCUI
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4-10 FI SYSTEM DIAGNOSISFI SYSTEM T
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4-12 FI SYSTEM DIAGNOSISFI SYSTEM P
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4-14 FI SYSTEM DIAGNOSISFI SYSTEM W
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4-16 FI SYSTEM DIAGNOSISSELF-DIAGNO
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4-18 FI SYSTEM DIAGNOSISCODE MALFUN
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4-20 FI SYSTEM DIAGNOSISFAIL-SAFE F
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4-22 FI SYSTEM DIAGNOSISFI SYSTEM T
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4-24 FI SYSTEM DIAGNOSISSELF-DIAGNO
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4-26 FI SYSTEM DIAGNOSISUSE OF SDS
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4-28 FI SYSTEM DIAGNOSISMALFUNCTION
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4-30 FI SYSTEM DIAGNOSISDTC No.C29P
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4-32 FI SYSTEM DIAGNOSIS“C11” (
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4-38 FI SYSTEM DIAGNOSIS6) Disconne
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4-40 FI SYSTEM DIAGNOSISStep 31) Tu
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4-44 FI SYSTEM DIAGNOSISStep 1 (Whe
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4-46 FI SYSTEM DIAGNOSISAre the con
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4-66 FI SYSTEM DIAGNOSISACTIVE CONT
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4-68 FI SYSTEM DIAGNOSIS STP sensor
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M4-76 FI SYSTEM DIAGNOSIS“C41”
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4-80 FI SYSTEM DIAGNOSIS6) Remove t
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4-86 FI SYSTEM DIAGNOSISACTIVE CONT
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4-88 FI SYSTEM DIAGNOSISECT SENSOR
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4-90 FI SYSTEM DIAGNOSISHO2 SENSOR
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5-2 FUEL SYSTEM AND THROTTLE BODYFU
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5-8 FUEL SYSTEM AND THROTTLE BODYRE
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5-10 FUEL SYSTEM AND THROTTLE BODY
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5-12 FUEL SYSTEM AND THROTTLE BODYT
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5-14 FUEL SYSTEM AND THROTTLE BODY
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FUEL SYSTEM AND THROTTLE BODY 5-17T
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FUEL SYSTEM AND THROTTLE BODY 5-19T
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FUEL SYSTEM AND THROTTLE BODY 5-21F
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FUEL SYSTEM AND THROTTLE BODY 5-23
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FUEL SYSTEM AND THROTTLE BODY 5-25S
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6-2 EXHAUST SYSTEMPRECAUTIONS FOR E
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6-4 EXHAUST SYSTEM• Remove the mu
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COOLING AND LUBRICATION SYSTEM 7-1C
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COOLING AND LUBRICATION SYSTEM 7-3C
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COOLING AND LUBRICATION SYSTEM 7-5R
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COOLING AND LUBRICATION SYSTEM 7-7E
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COOLING AND LUBRICATION SYSTEM 7-9T
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COOLING AND LUBRICATION SYSTEM 7-11
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8-2 CHASSISCHASSISCONTENTSREAR SUSP
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8-4 CHASSIS• Disconnect the turn
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8-6 CHASSISFRONT WHEELCONSTRUCTION1
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8-8 CHASSISINSPECTION AND DISASSEMB
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8-10 CHASSISREASSEMBLY AND INSTALLA
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8-12 CHASSISWHEELInstall the front
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8-14 CHASSISREMOVAL AND DISASSEMBLY
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8-16 CHASSIS• Remove the cylinder
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8-18 CHASSIS• Insert the inner tu
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8-20 CHASSISFRONT FORK CAP BOLT•
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8-22 CHASSISREMOVAL• Remove the f
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8-24 CHASSISREASSEMBLYReassemble th
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8-26 CHASSISSTEERING TENSION ADJUST
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8-28 CHASSISREMOVAL• Remove the f
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8-30 CHASSISAfter installing the ha
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8-32 CHASSISREMOVAL• Loosen the a
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8-34 CHASSISBEARINGSInspect the whe
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8-36 CHASSISBEARINGS• Apply SUZUK
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8-38 CHASSISBRAKE DISC• Apply THR
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8-40 CHASSISREMOVAL• Remove the u
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8-42 CHASSISSUSPENSION SETTINGAfter
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8-44 CHASSISREMOVAL• Remove the s
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8-46 CHASSISINSPECTION AND DISASSEM
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8-48 CHASSISPLATE• Inspect the pl
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8-50 CHASSISSWINGARM BEARING• Pre
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8-52 CHASSISSHOCK ABSORBER AND CUSH
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8-54 CHASSIS* This brake system is
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8-56 CHASSISCALIPER REMOVAL• Remo
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8-58 CHASSISPISTON SEAL• Install
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8-60 CHASSISMASTER CYLINDER REMOVAL
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8-62 CHASSISMASTER CYLINDER REASSEM
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8-64 CHASSISREAR BRAKECONSTRUCTION1
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8-66 CHASSIS• Install new brake p
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8-68 CHASSISCALIPER INSPECTIONBRAKE
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8-70 CHASSIS• Remove the front fo
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8-72 CHASSIS• Rout the rear brake
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8-74 CHASSISVALVE INSPECTION• Ins
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8-76 CHASSIS• In this condition,
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8-78 CHASSIS• Place the drive cha
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8-80 CHASSIS• Stake the joint pin
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9-2 ELECTRICAL SYSTEMELECTRICAL SYS
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9-4 ELECTRICAL SYSTEMSEMI-CONDUCTOR
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9-6 ELECTRICAL SYSTEMLOCATION OF EL
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9-8 ELECTRICAL SYSTEMCHARGING SYSTE
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9-10 ELECTRICAL SYSTEMREGULATED VOL
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9-12 ELECTRICAL SYSTEMSTARTER SYSTE
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9-14 ELECTRICAL SYSTEMSTARTER MOTOR
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9-16 ELECTRICAL SYSTEM• Align the
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9-18 ELECTRICAL SYSTEMGEAR POSITION
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9-20 ELECTRICAL SYSTEMIGNITION SYST
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9-22 ELECTRICAL SYSTEMOperationWhen
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9-24 ELECTRICAL SYSTEMStep 51) Insp
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9-26 ELECTRICAL SYSTEMNOTE:Use the
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9-28 ELECTRICAL SYSTEMIf the peak v
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9-30 ELECTRICAL SYSTEMREMOVAL AND D
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9-32 ELECTRICAL SYSTEMENGINE COOLAN
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9-34 ELECTRICAL SYSTEMSPEEDOMETERIf
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9-36 ELECTRICAL SYSTEMHEADLIGHT BEA
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9-38 ELECTRICAL SYSTEMIGNITION SWIT
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9-40 ELECTRICAL SYSTEMBATTERYSPECIF
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9-42 ELECTRICAL SYSTEMSERVICINGVisu
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10-2 SERVICING INFORMATIONTROUBLESH
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10-4 SERVICING INFORMATIONDTC No.C2
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10-6 SERVICING INFORMATIONENGINECom
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10-8 SERVICING INFORMATIONComplaint
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10-10 SERVICING INFORMATIONComplain
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10-12 SERVICING INFORMATIONRADIATOR
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10-14 SERVICING INFORMATIONBRAKESCo
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10-16 SERVICING INFORMATIONBATTERYC
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10-18 SERVICING INFORMATION26 N·m
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10-20 SERVICING INFORMATIONCABLE RO
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10-22 SERVICING INFORMATIONFUEL TAN
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10-24 SERVICING INFORMATIONFRONT BR
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10-26 SERVICING INFORMATIONFUEL TAN
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10-28 SERVICING INFORMATIONREAR FEN
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10-30 SERVICING INFORMATIONSIDE-STA
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10-32 SERVICING INFORMATIONREAR COM
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10-34 SERVICING INFORMATION09913-10
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10-36 SERVICING INFORMATION09940-40
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10-38 SERVICING INFORMATIONITEM N·
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10-40 SERVICING INFORMATIONTIGHTENI
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10-42 SERVICING INFORMATIONCYLINDER
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10-44 SERVICING INFORMATIONTHERMOST
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10-46 SERVICING INFORMATIONTHROTTLE
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10-48 SERVICING INFORMATIONTIRECold
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EMISSION CONTROL INFORMATION 11-1EM
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EMISSION CONTROL INFORMATION 11-3CR
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EMISSION CONTROL INFORMATION 11-5NO
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EMISSION CONTROL INFORMATION 11-7PA
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EMISSION CONTROL INFORMATION 11-9HE
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Prepared byOctober, 2005Part No. 99
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