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9-18 ELECTRICAL SYSTEMGEAR POSITION SWITCH• Disconnect the gear position switch coupler 1 and check thecontinuity between Bl and B/W with the transmission in neutral. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test ()ON (Neutral)OFF (Except neutral)BlB/WWhen disconnecting and connecting the gear positionswitch coupler, make sure to turn OFF the ignitionswitch, or electronic parts may get damaged.• Connect the gear position switch coupler to the wiring harness.• Turn the ignition switch to ON position and side-stand toupright position.• Measure the voltage between P and B/W lead wires using themulti-circuit tester when shifting the gearshift lever from low totop. 09900-25008: Multi-circuit tester set09900-25009: Needle pointed probe set Tester knob indication: Voltage () Gear position switch voltage: 0.6 V and more* Low to top gear position (P + – B/W -)* Except neutral position (P + – B/W -)VUse the special tool, to prevent the rubber of the waterproof coupler from damage.
ELECTRICAL SYSTEM 9-19TURN SIGNAL/SIDE-STAND RELAYThe turn signal/side-stand relay is composed of the turn signalrelay, side-stand relay and diode.• Lift and support the fuel tank. (5-3)• Remove the turn signal/side-stand relay 1.SIDE-STAND RELAY INSPECTIONFirst check the insulation between D and E terminals with thetester. Then apply 12 V to terminals D and C (+ to D and - toC) and check the continuity between D and E. If there is nocontinuity, replace the turn signal/side-stand relay with a newone. 09900-25008: Multi-circuit tester set Tester knob indication: Continuity test ()SIDE-STAND RELAYDIODETURNSIGNALRELAYDIODE INSPECTIONMeasure the voltage between the terminals using the multi-circuittester. Refer to the following table.- Probe oftester to:C, BA+ Probe of tester to:C, B A1.4 V and more(Tester’s battery voltage)0.4 – 0.6 V 09900-25008: Multi-circuit tester set Tester knob indication: Diode test ()NOTE:If the multi circuit tester reads 1.4 V and below when the testerprobes are not connected, replace its battery.
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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•
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8-22 CHASSISREMOVAL• Remove the f
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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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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
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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 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
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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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