general information - Martin Nez

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FUEL SYSTEM AND THROTTLE BODY 5-3FUEL SYSTEMFUEL TANK LIFT-UP• Remove the seat. (8-3)• Remove the frame covers. (8-4)• Remove the fuel tank cover/turn signal light assemblies.(8-3)• Take out the fuel tank prop stay 1• Lift and support the fuel tank with the fuel tank prop stay.FUEL TANK REMOVAL• Lift and support the fuel tank. (above)• Disconnect the fuel pump lead wire coupler 1.• Disconnect the fuel tank breather hose 2 and fuel tank drainhose 3.• Place a rag under the fuel feed hose 4 and disconnect thefuel feed hose.When removing the fuel tank, do not leave the fuelfeed hose 4 on the fuel tank side.Gasoline is highly flammable and explosive.Keep heat, spark and flame away.• Remove the fuel tank bracket mounting bolt.• Remove the fuel tank.FUEL TANK INSTALLATION• Installation is in the reverse order of removal.
5-4 FUEL SYSTEM AND THROTTLE BODYFUEL PRESSURE INSPECTION• Lift and support the fuel tank. (5-3)• Place a rag under the fuel feed hose 1 and remove the fuelfeed hose.• Install the special tools between the fuel tank and fuel deliverypipe. 09940-40211: Fuel pressure gauge adaptor09940-40220: Fuel pressure gauge hose attachment09915-77331: Oil pressure gauge09915-74521: Oil pressure gauge hoseTurn the ignition switch ON and check the fuel pressure. Fuel pressure: Approx. 300 kPa (3.0 kgf/cm 2 )If the fuel pressure is lower than the specification, inspect thefollowing items:* Fuel hose leakage* Clogged fuel filter* Pressure regulator* Fuel pumpIf the fuel pressure is higher than the specification, inspect thefollowing items:* Fuel pump check valve* Pressure regulator* Before removing the special tools, turn the ignitionswitch to OFF position and release the fuel pressureslowly.* Gasoline is highly flammable and explosive. Keepheat, sparks and flame away.A To fuel tankB To fuel delivery pipe
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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
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ENGINE 3-61 Crank pin O.D.CodeO.D.
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ENGINE 3-63• Check the correspond
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ENGINE 3-65CRANKSHAFT THRUST BEARIN
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ENGINE 3-67ENGINE REASSEMBLY• Rea
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ENGINE 3-69• Install the pistons
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ENGINE 3-71• Insert the right and
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ENGINE 3-73• Install the regulato
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ENGINE 3-75• Apply SUZUKI BOND to
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ENGINE 3-77OIL STRAINER• Install
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ENGINE 3-79CRANKCASE BREATHER COVER
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ENGINE 3-81• Apply SUZUKI BOND to
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ENGINE 3-83CAM CHAIN DRIVE SPROCKET
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ENGINE 3-85• Install the starter
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ENGINE 3-87OIL PUMP• Install the
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ENGINE 3-89• Lock the clutch slee
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ENGINE 3-91• Install the pressure
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ENGINE 3-93• Apply SUZUKI SUPER G
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ENGINE 3-95• Pull the cam chain l
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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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Page 233 and 234: 4-80 FI SYSTEM DIAGNOSIS6) Remove t
Page 239 and 240: 4-86 FI SYSTEM DIAGNOSISACTIVE CONT
Page 241 and 242: 4-88 FI SYSTEM DIAGNOSISECT SENSOR
Page 243 and 244: 4-90 FI SYSTEM DIAGNOSISHO2 SENSOR
Page 245: 5-2 FUEL SYSTEM AND THROTTLE BODYFU
Page 249 and 250: 5-6 FUEL SYSTEM AND THROTTLE BODYFU
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Page 253 and 254: 5-10 FUEL SYSTEM AND THROTTLE BODY
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Page 260 and 261: FUEL SYSTEM AND THROTTLE BODY 5-17T
Page 262 and 263: FUEL SYSTEM AND THROTTLE BODY 5-19T
Page 264 and 265: FUEL SYSTEM AND THROTTLE BODY 5-21F
Page 266 and 267: FUEL SYSTEM AND THROTTLE BODY 5-23
Page 268 and 269: FUEL SYSTEM AND THROTTLE BODY 5-25S
Page 270 and 271: 6-2 EXHAUST SYSTEMPRECAUTIONS FOR E
Page 272 and 273: 6-4 EXHAUST SYSTEM• Remove the mu
Page 274 and 275: COOLING AND LUBRICATION SYSTEM 7-1C
Page 276 and 277: COOLING AND LUBRICATION SYSTEM 7-3C
Page 278 and 279: COOLING AND LUBRICATION SYSTEM 7-5R
Page 280 and 281: COOLING AND LUBRICATION SYSTEM 7-7E
Page 282 and 283: COOLING AND LUBRICATION SYSTEM 7-9T
Page 284 and 285: 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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