general information - Martin Nez

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8-26 CHASSISSTEERING TENSION ADJUSTMENTCheck the steering movement in the following procedure.• By supporting the motorcycle with a jack, lift the front wheeluntil it is off the floor by 20 – 30 mm.• Check that the cables and wire harnesses are properlyrouted.• With the front wheel in the straight ahead state, hitch thespring scale (special tool) on one handlebar grip end asshown in the figure and read the graduation when the handlebarstarts moving. Do the same on the other grip end. Initial force: 200 – 500 grams 09940-92720: Spring scale• If the initial force read on the scale when the handlebar startsturning is either too heavy or too light, adjust it till it satisfiesthe specification.1) First, loosen the front fork upper clamp bolts, handlebarclamp bolts, steering stem head nut and steering stemlock-nut, and then adjust the steering stem nut by looseningor tightening it.2) Tighten the steering stem lock-nut, stem head nut, handlebarclamp bolts and front fork upper clamp bolts to the specifiedtorque and re-check the initial force with the spring scaleaccording to the previously described procedure.3) If the initial force is found within the specified range, adjustmenthas been completed.NOTE:Hold the front fork legs, move them back and forth and makesure that the steering is not loose.
CHASSIS 8-27HANDLEBARSCONSTRUCTION1 Handlebars 5 Left handlebar switch2 Rear view mirror 6 Right handlebar switch3 Handlebar balancer 7 Right handlebar grip4 Left handlebar grip
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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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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
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 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 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
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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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