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FI SYSTEM DIAGNOSIS 4-1FI SYSTEM DIAGNOSISCONTENTSPRECAUTIONS IN SERVICING .................................................................. 4- 3ELECTRICAL PARTS ........................................................................... 4- 3FUSE...................................................................................................... 4- 4ECM/VARIOUS SENSORS ................................................................... 4- 4ELECTRICAL CIRCUIT INSPECTION PROCEDURE.......................... 4- 6USING THE MULTI-CIRCUIT TESTER................................................. 4- 9FI SYSTEM TECHNICAL FEATURES......................................................... 4-10INJECTION TIME (INJECTION VOLUME) ........................................... 4-10COMPENSATION OF INJECTION TIME (VOLUME) ........................... 4-11INJECTION STOP CONTROL .............................................................. 4-11FI SYSTEM PARTS LOCATION ........................................................... 4-12FI SYSTEM WIRING DIAGRAM............................................................ 4-14ECM TERMINAL .......................................................................................... 4-15SELF-DIAGNOSIS FUNCTION.................................................................... 4-16USER MODE ......................................................................................... 4-16DEALER MODE..................................................................................... 4-17TPS ADJUSTMENT............................................................................... 4-19FAIL-SAFE FUNCTION ............................................................................... 4-20FI SYSTEM TROUBLESHOOTING ............................................................. 4-22CUSTOMER COMPLAINT ANALYSIS ................................................. 4-22VISUAL INSPECTION ........................................................................... 4-23SELF-DIAGNOSTIC PROCEDURES.................................................... 4-24SELF-DIAGNOSIS RESET PROCEDURE............................................ 4-24USE OF SDS DIAGNOSTIC PROCEDURES ....................................... 4-25USE OF SDS DIAGNOSIS RESET PROCEDURE ............................... 4-26SHOW DATA WHEN TROUBLE(DISPLAING DATA AT THE TIME OF DTC) ........................................ 4-27MALFUNCTION CODE AND DEFECTIVE CONDITION ...................... 4-28“C11” (P0340) CMP SENSOR CIRCUIT MALFUNCTION ................... 4-32“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION ................... 4-34“C13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION .............. 4-36“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION ............... 4-42“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION............. 4-47“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION .............. 4-51“C22” (P1450-H/L) AP SENSOR CIRCUIT MALFUNCTION ............... 4-55“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION ............... 4-60“C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354)IGNITION SYSTEM MALFUNCTION .................................................... 4-63“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION ............... 4-64“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION ............. 4-674
4-2 FI SYSTEM DIAGNOSISFI SYSTEM DIAGNOSISCONTENTS“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION....................... 4-72“C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204)FUEL INJECTOR CIRCUIT MALFUNCTION....................................... 4-74“C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION .................. 4-76“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION(Only for Immobilizer) .......................................................................... 4-78“C44” (P0130/P0135) HO2 SENSOR (HO2S)CIRCUIT MALFUNCTION ..................................................................... 4-79“C49” (P1656) PAIR CONTROL SOLENOID VALVECIRCUIT MALFUNCTION ..................................................................... 4-83“C60” (P0480) COOLING FAN RELAYCIRCUIT MALFUNCTION ..................................................................... 4-85SENSORS .................................................................................................... 4-87CMP SENSOR INSPECTION ................................................................ 4-87CMP SENSOR REMOVAL AND INSTALLATION................................ 4-87CKP SENSOR INSPECTION ................................................................ 4-87CKP SENSOR REMOVAL AND INSTALLATION ................................ 4-87IAP SENSOR INSPECTION .................................................................. 4-87IAP SENSOR REMOVAL AND INSTALLATION.................................. 4-87TP SENSOR INSPECTION ................................................................... 4-87TP SENSOR REMOVAL AND INSTALLATION ................................... 4-87TPS ADJUSTMENT............................................................................... 4-87ECT SENSOR INSPECTION................................................................. 4-88ECT SENSOR REMOVAL AND INSTALLATION................................. 4-88IAT SENSOR INSPECTION .................................................................. 4-88IAT SENSOR REMOVAL AND INSTALLATION .................................. 4-88AP SENSOR INSPECTION ................................................................... 4-88AP SENSOR REMOVAL AND INSTALLATION................................... 4-88TO SENSOR INSPECTION ................................................................... 4-89TO SENSOR REMOVAL AND INSTALLATION................................... 4-89STP SENSOR INSPECTION ................................................................. 4-89STP SENSOR REMOVAL AND INSTALLATION................................. 4-89STP SENSOR ADJUSTMENT .............................................................. 4-89HO2 SENSOR INSPECTION................................................................. 4-89HO2 SENSOR REMOVAL/INSTALLATION ......................................... 4-90
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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
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ENGINE 3-13• Replace the exhaust
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ENGINE 3-15CAMSHAFTS• Remove the
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ENGINE 3-17CLUTCH• Remove the clu
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ENGINE 3-19• Remove the thrust wa
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ENGINE 3-21• Remove the starter c
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ENGINE 3-23GEAR POSITION SWITCH•
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ENGINE 3-25MIDDLE CRANKCASE• Remo
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ENGINE 3-27ENGINE COMPONENTS INSPEC
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ENGINE 3-29CAMSHAFT JOURNAL WEAR•
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ENGINE 3-31CAM CHAIN TENSIONERINSPE
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ENGINE 3-33VALVE STEM RUNOUT• Sup
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ENGINE 3-35• Cool down the new va
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ENGINE 3-37• Clean and assemble t
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ENGINE 3-39INTAKE PIPE• Remove th
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ENGINE 3-41CLUTCH BEARING INSPECTIO
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ENGINE 3-43WATER PUMPDISASSEMBLY/IN
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ENGINE 3-45TRANSMISSIONDISASSEMBLYD
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ENGINE 3-47TRANSMISSION PARTS LOCAT
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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 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
Page 151 and 152: ENGINE 3-99A Cam chain tension adju
Page 153: ENGINE 3-101• Tighten the head co
Page 157 and 158: 4-4 FI SYSTEM DIAGNOSIS• When con
Page 159 and 160: 4-6 FI SYSTEM DIAGNOSISELECTRICAL C
Page 161 and 162: 4-8 FI SYSTEM DIAGNOSISSHORT CIRCUI
Page 163 and 164: 4-10 FI SYSTEM DIAGNOSISFI SYSTEM T
Page 165 and 166: 4-12 FI SYSTEM DIAGNOSISFI SYSTEM P
Page 167 and 168: 4-14 FI SYSTEM DIAGNOSISFI SYSTEM W
Page 169 and 170: 4-16 FI SYSTEM DIAGNOSISSELF-DIAGNO
Page 171 and 172: 4-18 FI SYSTEM DIAGNOSISCODE MALFUN
Page 173 and 174: 4-20 FI SYSTEM DIAGNOSISFAIL-SAFE F
Page 175 and 176: 4-22 FI SYSTEM DIAGNOSISFI SYSTEM T
Page 177 and 178: 4-24 FI SYSTEM DIAGNOSISSELF-DIAGNO
Page 179 and 180: 4-26 FI SYSTEM DIAGNOSISUSE OF SDS
Page 181 and 182: 4-28 FI SYSTEM DIAGNOSISMALFUNCTION
Page 183 and 184: 4-30 FI SYSTEM DIAGNOSISDTC No.C29P
Page 185 and 186: 4-32 FI SYSTEM DIAGNOSIS“C11” (
Page 191 and 192: 4-38 FI SYSTEM DIAGNOSIS6) Disconne
Page 193 and 194: 4-40 FI SYSTEM DIAGNOSISStep 31) Tu
Page 197 and 198: 4-44 FI SYSTEM DIAGNOSISStep 1 (Whe
Page 199 and 200: 4-46 FI SYSTEM DIAGNOSISAre the con
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Page 203 and 204: 4-50 FI SYSTEM DIAGNOSISStep 21) Tu
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4-52 FI SYSTEM DIAGNOSISStep 1 (Whe
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4-54 FI SYSTEM DIAGNOSISStep 21) Tu
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4-56 FI SYSTEM DIAGNOSIS4) Disconne
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4-58 FI SYSTEM DIAGNOSIS7) Disconne
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4-60 FI SYSTEM DIAGNOSIS“C23” (
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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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