general information - Martin Nez

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FOREWORDThis manual contains an introductory description onthe SUZUKI GSR600 and procedures for its inspection/serviceand overhaul of its main components.Other information considered as generally known isnot included.Read the GENERAL INFORMATION section tofamiliarize yourself with the motorcycle and its maintenance.Use this section as well as other sectionsto use as a guide for proper inspection and service.This manual will help you know the motorcycle betterso that you can assure your customers of fastand reliable service.* This manual has been prepared on the basisof the latest specifications at the time of publication.If modifications have been made sincethen, differences may exist between the contentof this manual and the actual motorcycle.* Illustrations in this manual are used to showthe basic principles of operation and workprocedures. They may not represent theactual motorcycle exactly in detail.* This manual is written for persons who haveenough knowledge, skills and tools, includingspecial tools, for servicing SUZUKI motorcycles.If you do not have the proper knowledgeand tools, ask your authorized SUZUKImotorcycle dealer to help you.Inexperienced mechanics or mechanicswithout the proper tools and equipmentmay not be able to properly perform theservices described in this manual.Improper repair may result in injury to themechanic and may render the motorcycleunsafe for the rider and passenger.GROUP INDEXGENERAL INFORMATION 1PERIODIC MAINTENANCE 2ENGINE 3FI SYSTEM DIAGNOSIS 4FUEL SYSTEM AND THROTTLEBODY5EXHAUST SYSTEM 6COOLING AND LUBRICATIONSYSTEM7CHASSIS 8ELECTRICAL SYSTEM 9SERVICING INFORMATION 10EMISSION CONTROLINFORMATION11WIRING DIAGRAM 12© COPYRIGHT SUZUKI MOTOR CORPORATION 2005
HOW TO USE THIS MANUALTO LOCATE WHAT YOU ARE LOOKING FOR:1. The text of this manual is divided into sections.2. The section titles are listed in the GROUP INDEX.3. Holding the manual as shown at the right will allow you to findthe first page of the section easily.4. The contents are listed on the first page of each section tohelp you find the item and page you need.COMPONENT PARTS AND WORK TO BE DONEUnder the name of each system or unit, is its exploded view. Work instructions and other service informationsuch as the tightening torque, lubricating points and locking agent points, are provided.Example: Front wheel1 Front axle2 Brake disc3 Dust seal4 Bearing5 Front wheel6 Spacer7 CollarA Brake disc boltITEM N·m kgf-m1 100 10.0A 23 2.3
Page 1: GSR60099500-36160-01E
Page 6 and 7: MMAL-CodeMaxMILMinNNOXOOHCOPSPPCVRS
Page 8: GENERAL INFORMATION 1-1GENERAL INFO
Page 11 and 12: 1-4 GENERAL INFORMATIONSUZUKI GSR60
Page 13 and 14: 1-6 GENERAL INFORMATIONENGINE COOLA
Page 15 and 16: 1-8 GENERAL INFORMATIONINFORMATION
Page 17 and 18: 1-10 GENERAL INFORMATIONCHASSISFron
Page 19 and 20: 2-2 PERIODIC MAINTENANCEPERIODIC MA
Page 21 and 22: 2-4 PERIODIC MAINTENANCEMAINTENANCE
Page 23 and 24: 2-6 PERIODIC MAINTENANCESPARK PLUG
Page 25 and 26: 2-8 PERIODIC MAINTENANCE• Remove
Page 27 and 28: 2-10 PERIODIC MAINTENANCENOTE:* Be
Page 29 and 30: 2-12 PERIODIC MAINTENANCE(EXHAUST S
Page 31 and 32: 2-14 PERIODIC MAINTENANCEOIL FILTER
Page 33 and 34: 2-16 PERIODIC MAINTENANCECLUTCHInsp
Page 35 and 36: 2-18 PERIODIC MAINTENANCEAIR BLEEDI
Page 37 and 38: 2-20 PERIODIC MAINTENANCE• Count
Page 39 and 40: 2-22 PERIODIC MAINTENANCEBRAKE(BRAK
Page 41 and 42: 2-24 PERIODIC MAINTENANCEBRAKE LIGH
Page 43 and 44: 2-26 PERIODIC MAINTENANCETIRESInspe
Page 45 and 46: 2-28 PERIODIC MAINTENANCEEXHAUST PI
Page 47 and 48: 2-30 PERIODIC MAINTENANCE
Page 49 and 50: 2-32 PERIODIC MAINTENANCEOIL PRESSU
Page 51 and 52: 2-34 PERIODIC MAINTENANCEData at 3
Page 53 and 54:
ENGINE 3-1ENGINECONTENTSENGINE COMP
Page 55 and 56:
ENGINE 3-3ENGINE REMOVAL AND INSTAL
Page 57 and 58:
ENGINE 3-5• Remove the front engi
Page 59 and 60:
ENGINE 3-7ENGINE SPROCKET AND GEAR
Page 61 and 62:
ENGINE 3-9• Remove the engine mou
Page 63 and 64:
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 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
Page 155 and 156:
4-2 FI SYSTEM DIAGNOSISFI SYSTEM DI
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 187 and 188:
Page 189 and 190:
Page 191 and 192:
4-38 FI SYSTEM DIAGNOSIS6) Disconne
Page 193 and 194:
4-40 FI SYSTEM DIAGNOSISStep 31) Tu
Page 195 and 196:
Page 197 and 198:
4-44 FI SYSTEM DIAGNOSISStep 1 (Whe
Page 199 and 200:
4-46 FI SYSTEM DIAGNOSISAre the con
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
4-66 FI SYSTEM DIAGNOSISACTIVE CONT
Page 221 and 222:
4-68 FI SYSTEM DIAGNOSIS STP sensor
Page 223 and 224:
Page 225 and 226:
Page 227 and 228:
Page 229 and 230:
M4-76 FI SYSTEM DIAGNOSIS“C41”
Page 231 and 232:
Page 233 and 234:
4-80 FI SYSTEM DIAGNOSIS6) Remove t
Page 235 and 236:
Page 237 and 238:
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 247 and 248:
Page 249 and 250:
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
Page 257:
5-14 FUEL SYSTEM AND THROTTLE BODY
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
Page 286 and 287:
Page 288 and 289:
Page 290 and 291:
Page 292 and 293:
Page 294 and 295:
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
Page 320 and 321:
8-26 CHASSISSTEERING TENSION ADJUST
Page 322 and 323:
8-28 CHASSISREMOVAL• Remove the f
Page 324 and 325:
8-30 CHASSISAfter installing the ha
Page 326 and 327:
8-32 CHASSISREMOVAL• Loosen the a
Page 328 and 329:
8-34 CHASSISBEARINGSInspect the whe
Page 330 and 331:
8-36 CHASSISBEARINGS• Apply SUZUK
Page 332 and 333:
8-38 CHASSISBRAKE DISC• Apply THR
Page 334 and 335:
8-40 CHASSISREMOVAL• Remove the u
Page 336 and 337:
8-42 CHASSISSUSPENSION SETTINGAfter
Page 338 and 339:
8-44 CHASSISREMOVAL• Remove the s
Page 340 and 341:
8-46 CHASSISINSPECTION AND DISASSEM
Page 342 and 343:
8-48 CHASSISPLATE• Inspect the pl
Page 344 and 345:
8-50 CHASSISSWINGARM BEARING• Pre
Page 346 and 347:
8-52 CHASSISSHOCK ABSORBER AND CUSH
Page 348 and 349:
8-54 CHASSIS* This brake system is
Page 350 and 351:
8-56 CHASSISCALIPER REMOVAL• Remo
Page 352 and 353:
8-58 CHASSISPISTON SEAL• Install
Page 354 and 355:
8-60 CHASSISMASTER CYLINDER REMOVAL
Page 356 and 357:
8-62 CHASSISMASTER CYLINDER REASSEM
Page 358 and 359:
8-64 CHASSISREAR BRAKECONSTRUCTION1
Page 360 and 361:
8-66 CHASSIS• Install new brake p
Page 362 and 363:
8-68 CHASSISCALIPER INSPECTIONBRAKE
Page 364 and 365:
8-70 CHASSIS• Remove the front fo
Page 366 and 367:
8-72 CHASSIS• Rout the rear brake
Page 368 and 369:
8-74 CHASSISVALVE INSPECTION• Ins
Page 370 and 371:
8-76 CHASSIS• In this condition,
Page 372 and 373:
8-78 CHASSIS• Place the drive cha
Page 374 and 375:
8-80 CHASSIS• Stake the joint pin
Page 376 and 377:
9-2 ELECTRICAL SYSTEMELECTRICAL SYS
Page 378 and 379:
9-4 ELECTRICAL SYSTEMSEMI-CONDUCTOR
Page 380 and 381:
9-6 ELECTRICAL SYSTEMLOCATION OF EL
Page 382 and 383:
9-8 ELECTRICAL SYSTEMCHARGING SYSTE
Page 384 and 385:
9-10 ELECTRICAL SYSTEMREGULATED VOL
Page 386 and 387:
9-12 ELECTRICAL SYSTEMSTARTER SYSTE
Page 388 and 389:
9-14 ELECTRICAL SYSTEMSTARTER MOTOR
Page 390 and 391:
9-16 ELECTRICAL SYSTEM• Align the
Page 392 and 393:
9-18 ELECTRICAL SYSTEMGEAR POSITION
Page 394 and 395:
9-20 ELECTRICAL SYSTEMIGNITION SYST
Page 396 and 397:
9-22 ELECTRICAL SYSTEMOperationWhen
Page 398 and 399:
9-24 ELECTRICAL SYSTEMStep 51) Insp
Page 400 and 401:
9-26 ELECTRICAL SYSTEMNOTE:Use the
Page 402 and 403:
9-28 ELECTRICAL SYSTEMIf the peak v
Page 404 and 405:
9-30 ELECTRICAL SYSTEMREMOVAL AND D
Page 406 and 407:
9-32 ELECTRICAL SYSTEMENGINE COOLAN
Page 408 and 409:
9-34 ELECTRICAL SYSTEMSPEEDOMETERIf
Page 410 and 411:
9-36 ELECTRICAL SYSTEMHEADLIGHT BEA
Page 412 and 413:
9-38 ELECTRICAL SYSTEMIGNITION SWIT
Page 414 and 415:
9-40 ELECTRICAL SYSTEMBATTERYSPECIF
Page 416 and 417:
9-42 ELECTRICAL SYSTEMSERVICINGVisu
Page 418 and 419:
10-2 SERVICING INFORMATIONTROUBLESH
Page 420 and 421:
10-4 SERVICING INFORMATIONDTC No.C2
Page 422 and 423:
10-6 SERVICING INFORMATIONENGINECom
Page 424 and 425:
10-8 SERVICING INFORMATIONComplaint
Page 426 and 427:
10-10 SERVICING INFORMATIONComplain
Page 428 and 429:
10-12 SERVICING INFORMATIONRADIATOR
Page 430 and 431:
10-14 SERVICING INFORMATIONBRAKESCo
Page 432 and 433:
10-16 SERVICING INFORMATIONBATTERYC
Page 434 and 435:
10-18 SERVICING INFORMATION26 N·m
Page 436 and 437:
10-20 SERVICING INFORMATIONCABLE RO
Page 438 and 439:
10-22 SERVICING INFORMATIONFUEL TAN
Page 440 and 441:
10-24 SERVICING INFORMATIONFRONT BR
Page 442 and 443:
10-26 SERVICING INFORMATIONFUEL TAN
Page 444 and 445:
10-28 SERVICING INFORMATIONREAR FEN
Page 446 and 447:
10-30 SERVICING INFORMATIONSIDE-STA
Page 448 and 449:
10-32 SERVICING INFORMATIONREAR COM
Page 450 and 451:
10-34 SERVICING INFORMATION09913-10
Page 452 and 453:
10-36 SERVICING INFORMATION09940-40
Page 454 and 455:
10-38 SERVICING INFORMATIONITEM N·
Page 456 and 457:
10-40 SERVICING INFORMATIONTIGHTENI
Page 458 and 459:
10-42 SERVICING INFORMATIONCYLINDER
Page 460 and 461:
10-44 SERVICING INFORMATIONTHERMOST
Page 462 and 463:
10-46 SERVICING INFORMATIONTHROTTLE
Page 464 and 465:
10-48 SERVICING INFORMATIONTIRECold
Page 466 and 467:
EMISSION CONTROL INFORMATION 11-1EM
Page 468 and 469:
EMISSION CONTROL INFORMATION 11-3CR
Page 470 and 471:
EMISSION CONTROL INFORMATION 11-5NO
Page 472 and 473:
EMISSION CONTROL INFORMATION 11-7PA
Page 474 and 475:
EMISSION CONTROL INFORMATION 11-9HE
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Prepared byOctober, 2005Part No. 99
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