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3-64 ENGINE Crankshaft journal O.D. specificationCodeABCO.D. specification29.992 – 30.000 mm29.984 – 29.992 mm29.976 – 29.984 mm 09900-20202: Micrometer (25 – 50 mm) Bearing thickness specificationColor (Part No.)Yellow(12229-29G00-0D0)Brown(12229-29G00-0C0)Black(12229-29G00-0B0)Green(12229-29G00-0A0)Thickness1.500 – 1.504 mm1.496 – 1.500 mm1.492 – 1.496 mm1.488 – 1.492 mmNOTE:Upper and middle crankshaft journal bearings are the same.INSTALLATION• When fitting the crankshaft journal bearings to the upper andmiddle crankcases, be sure to fix the stopper part A first andpress the other end.Do not touch the bearing surfaces with your hands.Grasp by the edge of the bearing shell.
ENGINE 3-65CRANKSHAFT THRUST BEARING• With the crankshaft, right-side thrust bearing and left-sidethrust bearing inserted in the upper crankcase, measure thethrust clearance on the left side by using the thickness gauge.L: Left-side thrust bearingR: Right-side thrust bearingNOTE:Pull the crankshaft to the generator side, so that there is noclearance on the right-side thrust bearing. Thrust clearance:Standard: 0.055 – 0.110 mm 09900-20803: Thickness gauge• If the thrust clearance exceeds the standard range, adjust thethrust clearance by the following procedures.CRANKSHAFT THRUST CLEARANCE ADJUSTMENT• Remove the right-side thrust bearing and measure its thicknesswith a micrometer.• If the thickness of the right-side thrust bearing is below standard,replace it with a new one and once again perform thethrust clearance measurement listed above, checking tomake sure it is within standard. Right-side thrust bearing thickness:Standard: 2.425 – 2.450 mm 09900-20205: Micrometer (0 – 25 mm)• If the right-side thrust bearing is within the standard range,reinsert the right-side thrust bearing and remove the left-sidethrust bearing.• As shown in the illustration, measure the clearance by using athickness gauge before inserting of the left-side thrust bearing.• Select a left-side thrust bearing from the selection table.(3-66)
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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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2-32 PERIODIC MAINTENANCEOIL PRESSU
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2-34 PERIODIC MAINTENANCEData at 3
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ENGINE 3-1ENGINECONTENTSENGINE COMP
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ENGINE 3-3ENGINE REMOVAL AND INSTAL
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ENGINE 3-5• Remove the front engi
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ENGINE 3-7ENGINE SPROCKET AND GEAR
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ENGINE 3-9• Remove the engine mou
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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 and 100: ENGINE 3-47TRANSMISSION PARTS LOCAT
Page 101 and 102: ENGINE 3-49PISTON AND PISTON RINGPI
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: ENGINE 3-63• Check the correspond
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
Page 151 and 152: ENGINE 3-99A Cam chain tension adju
Page 153 and 154: ENGINE 3-101• Tighten the head co
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Page 157 and 158: 4-4 FI SYSTEM DIAGNOSIS• When con
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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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