general information - Martin Nez

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FI SYSTEM DIAGNOSIS 4-11COMPENSATION OF INJECTION TIME (VOLUME)The following different signals are output from the respective sensors for compensation of the fuel injectiontime (volume).SIGNALATMOSPHERIC PRESSURE SENSORSIGNALENGINE COOLANT TEMPERATURE SEN-SOR SIGNALINTAKE AIR TEMPERATURE SENSORSIGNALHEATED OXYGEN SENSOR SIGNALBATTERY VOLTAGE SIGNALENGINE RPM SIGNALSTARTING SIGNALACCELERATION SIGNAL/DECELERATION SIGNALDESCRIPTIONWhen atmospheric pressure is low, the sensor sends thesignal to the ECM and reduce the injection time (volume).When engine coolant temperature is low, injection time (volume)is increased.When intake air temperature is low, injection time (volume)is increased.Air/fuel ratio is compensated to the theoretical ratio fromdensity of oxygen in exhaust gasses. The compensationoccurs in such a way that more fuel is supplied if detectedair/fuel ratio is lean and less fuel is supplied if it is rich.ECM operates on the battery voltage and at the same time,it monitors the voltage signal for compensation of the fuelinjection time (volume). A longer injection time is needed toadjust injection volume in the case of low voltage.At high speed, the injection time (volume) is increased.When starting engine, additional fuel is injected duringcranking engine.During acceleration, the fuel injection time (volume) isincreased in accordance with the throttle opening speed andengine rpm. During deceleration, the fuel injection time (volume)is decreased.INJECTION STOP CONTROLSIGNALTIP-OVER SENSOR SIGNAL(FUEL SHUT-OFF)OVER-REV. LIMITER SIGNALDESCRIPTIONWhen the motorcycle tips over, the tip-over sensor sends asignal to the ECM. Then, this signal cuts OFF current suppliedto the fuel pump, fuel injectors and ignition coils.The fuel injectors stop operation when engine rpm reachesrev. limit rpm.
4-12 FI SYSTEM DIAGNOSISFI SYSTEM PARTS LOCATIONECMA SpeedometerB Engine coolant temperature sensor (ECTS)C Ignition coilD Speed sensorE Cam shaft position sensor (CMPS)F Intake air pressure sensor (IAPS)G Intake air temperature sensor (IATS)H Fuel injectorI HO2 sensor
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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
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ENGINE 3-51CRANKCASEGEARSHIFT FORK
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ENGINE 3-53• Remove the oil seal
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ENGINE 3-55OIL JETRemoval• Remove
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ENGINE 3-57• Remove the water jac
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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 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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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
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Page 177 and 178: 4-24 FI SYSTEM DIAGNOSISSELF-DIAGNO
Page 179 and 180: 4-26 FI SYSTEM DIAGNOSISUSE OF SDS
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Page 183 and 184: 4-30 FI SYSTEM DIAGNOSISDTC No.C29P
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Page 191 and 192: 4-38 FI SYSTEM DIAGNOSIS6) Disconne
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4-62 FI SYSTEM DIAGNOSISStep 1 (Whe
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4-64 FI SYSTEM DIAGNOSIS“C28” (
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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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4-70 FI SYSTEM DIAGNOSISStep 21) Tu
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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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4-82 FI SYSTEM DIAGNOSISStep 2 (Whe
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4-84 FI SYSTEM DIAGNOSISStep 21) Tu
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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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