general information - Martin Nez

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8-60 CHASSISMASTER CYLINDER REMOVAL ANDDISASSEMBLY• Drain brake fluid. (8-55)• Disconnect the front brake light switch lead wires 1.• Place a rag underneath the brake hose union bolt 2 on themaster cylinder to catch any split brake fluid. Remove thebrake hose union bolt 2 and disconnect the brake hose.Immediately and completely wipe off any brake fluidcontacting any part of the motorcycle. The fluid reactschemically with paint, plastics and rubber materials,etc. and will damage them severely.• Remove the right rear view mirror.• Remove the master cylinder assembly.• Remove the reservoir cap 3, plate 4 and diaphragm 5.• Remove the brake lever 6 and brake light switch 7.
CHASSIS 8-61• Pull out the dust boot 8 and remove the snap ring 9. 09900-06108: Snap ring pliers• Remove the piston/secondary cup, primary cup and spring.0 Secondary cupA PistonB Primary cupC SpringMASTER CYLINDER INSPECTIONMASTER CYLINDERInspect the master cylinder bore for any scratches or other damage.PISTONInspect the piston surface for any scratches or other damage.RUBBER PARTSInspect the primary cup, secondary cup and dust boot for wearor damage.
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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
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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
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 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
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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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