general information - Martin Nez

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6-2 EXHAUST SYSTEMPRECAUTIONS FOR EXHAUST SYSTEMTo avoid the danger of being burned, do not touch theexhaust system when the system is hot. Any serviceon the exhaust system should be performed when thesystem is cool.Make sure that the exhaust pipe and muffler haveenough clearance from the rubber parts and plasticparts to avoid melting.EXHAUST SYSTEM COMPONENTS (2-28)EXHAUST PIPE AND MUFFLERINSPECTIONInspect the exhaust pipe connection, muffler connection andHO2 sensor for exhaust gas leakage and mounting condition. Ifany defect is found, replace the defect part with a new one.• Tighten the exhaust pipe bolts, muffler mounting bolts, mufflerconnecting bolts and HO2 sensor to the specified torque.(6-5)
EXHAUST SYSTEM 6-3REMOVAL• Remove the radiator mounting bolts and move the radiatorforward. (3-4)• Remove the exhaust pipe bolts.• Remove the under covers. (8-5)• Remove the HO2 sensor 1.• Remove the exhaust pipe and muffler joint.• Remove the seat tail cover. (8-4)• Remove the muffler covers. (8-5)• Remove the taillight/turn signal light assembly 1.
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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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4-44 FI SYSTEM DIAGNOSISStep 1 (Whe
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4-46 FI SYSTEM DIAGNOSISAre the con
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Page 219 and 220: 4-66 FI SYSTEM DIAGNOSISACTIVE CONT
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Page 223 and 224: 4-70 FI SYSTEM DIAGNOSISStep 21) Tu
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Page 233 and 234: 4-80 FI SYSTEM DIAGNOSIS6) Remove t
Page 235 and 236: 4-82 FI SYSTEM DIAGNOSISStep 2 (Whe
Page 237 and 238: 4-84 FI SYSTEM DIAGNOSISStep 21) Tu
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 and 246: 5-2 FUEL SYSTEM AND THROTTLE BODYFU
Page 251 and 252: 5-8 FUEL SYSTEM AND THROTTLE BODYRE
Page 253 and 254: 5-10 FUEL SYSTEM AND THROTTLE BODY
Page 255 and 256: 5-12 FUEL SYSTEM AND THROTTLE BODYT
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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 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
Page 296 and 297: 8-2 CHASSISCHASSISCONTENTSREAR SUSP
Page 298 and 299: 8-4 CHASSIS• Disconnect the turn
Page 300 and 301: 8-6 CHASSISFRONT WHEELCONSTRUCTION1
Page 302 and 303: 8-8 CHASSISINSPECTION AND DISASSEMB
Page 304 and 305: 8-10 CHASSISREASSEMBLY AND INSTALLA
Page 306 and 307: 8-12 CHASSISWHEELInstall the front
Page 308 and 309: 8-14 CHASSISREMOVAL AND DISASSEMBLY
Page 310 and 311: 8-16 CHASSIS• Remove the cylinder
Page 312 and 313: 8-18 CHASSIS• Insert the inner tu
Page 314 and 315: 8-20 CHASSISFRONT FORK CAP BOLT•
Page 316 and 317: 8-22 CHASSISREMOVAL• Remove the f
Page 318 and 319: 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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