general information - Martin Nez

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9-40 ELECTRICAL SYSTEMBATTERYSPECIFICATIONSType designationCapacityFTX9-BS12 V, 28.8 kC (8 Ah)/10 HR1 Upper cover breather 5 Terminal2 Cathode plates 6 Safety valve3 Stopper 7 Anode plates4 Filter 8 Separator (Fiberglass plate)INITIAL CHARGINGFilling electrolyte• Remove the aluminum tape 1 sealing the battery electrolytefiller holes A.NOTE:When filling electrolyte, the battery must be removed from thevehicle and must be put on the level ground.• Remove the caps 2.NOTE:* After filling the electrolyte completely, use the removed cap 2as sealing caps of battery-filler holes.* Do not remove or pierce the sealed areas 3 of the electrolytecontainer.• Insert the nozzles of the electrolyte container 4 into the battery’selectrolyte filler holes, holding the container firmly sothat it does not fall. Take precaution not to allow any of thefluid to spill.• Make sure air bubbles 5 are coming up each electrolyte container,and leave in this position for about more than 20 minutes.
ELECTRICAL SYSTEM 9-41NOTE:If no air bubbles are coming up from a filler port, tap the bottomof the electrolyte container two or three times.Never remove the container from the battery.• After confirming that the electrolyte has entered the batterycompletely, remove the electrolyte containers from the battery.Wait for about 20 minutes.• Insert the caps 6 into the filler holes, pressing in firmly so thatthe top of the caps do not protrude above the upper surface ofthe battery’s top cover.* Never use anything except the specified battery.* Once the caps have been installed to the battery, donot remove the caps.* Do not tap the caps with a tool such as hammerwhen installing them.CORRECTINCORRECTFor initial charging, use the charger specially designed for MF battery.* For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise,the battery may be overcharged resulting in shortened service life.* Do not remove the cap during charging.* Position the battery with the cap facing upward during charging.
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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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8-48 CHASSISPLATE• Inspect the pl
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8-50 CHASSISSWINGARM BEARING• Pre
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8-52 CHASSISSHOCK ABSORBER AND CUSH
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8-54 CHASSIS* This brake system is
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8-56 CHASSISCALIPER REMOVAL• Remo
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8-58 CHASSISPISTON SEAL• Install
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8-60 CHASSISMASTER CYLINDER REMOVAL
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8-62 CHASSISMASTER CYLINDER REASSEM
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8-64 CHASSISREAR BRAKECONSTRUCTION1
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8-66 CHASSIS• Install new brake p
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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 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
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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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