general information - Martin Nez

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8-72 CHASSIS• Rout the rear brake hose properly. (10-25)• Adjust the brake pedal height. (2-23)• Tighten each bolt to the specified torque. Master cylinder rod lock-nut 1: 18 N·m (1.8 kgf-m)Front footrest bracket bolt 2: 23 N·m (2.3 kgf-m)Master cylinder mounting bolt 3: 10 N·m (1.0 kgf-m)Brake hose union bolt 4: 23 N·m (2.3 kgf-m)* The seal washers should be replaced with the newones to prevent fluid leakage.* Bleed air from the system after reassembling themaster cylinder. (2-25)
CHASSIS 8-73TIRE AND WHEELTIRE REMOVALThe most critical factor of tubeless tire is the seal between thewheel rim and the tire bead. For this reason, it is recommendedto use a tire changer that can satisfy this sealing requirementand can make the operation efficient as well as functional.For operating procedures, refer to the instructions supplied bythe tire changer manufacturer.NOTE:When removing the tire in the case of repair or inspection, markthe tire with a chalk to indicate the tire position relative to thevalve position.Even though the tire is refitted to the original position afterrepairing puncture, the tire may have to be balanced again sincesuch a repair can cause imbalance.INSPECTIONWHEELWipe the wheel clean and check for the following:• Distortion and crack• Any flaws and scratches at the bead seating area.• Wheel runout (8-8)TIRETire must be checked for the following points:• Nick and rupture on side wall• Tire tread depth (2-26)• Tread separation• Abnormal, uneven wear on tread• Surface damage on bead• Localized tread wear due to skidding (Flat spot)• Abnormal condition of inner liner
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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
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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•
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 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
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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
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Page 412 and 413: 9-38 ELECTRICAL SYSTEMIGNITION SWIT
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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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