general information - Martin Nez

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10-38 SERVICING INFORMATIONITEM N·m kgf-mOil gallery plug (M10) 11 1.1(M16) 35 3.5Oil drain plug 23 2.3Piston cooling oil jet bolt 10 1.0Oil pump mounting bolt 10 1.0Conrod bearing cap bolt (Initial) 15 1.5(Final)90° (1/4 turn)Bearing retainer screw 10 1.0Crankcase breather cover bolt 10 1.0Oil strainer bolt 10 1.0Oil pan bolt 10 1.0Oil cooler mounting bolt 10 1.0Water by-pass union 12 1.2Gearshift fork shaft retainer bolt 10 1.0Starter motor mounting bolt 10 1.0FI SYSTEM AND INTAKE AIR SYSTEMITEM N·m kgf-mCMP sensor bolt 11 1.1IAT sensor 18 1.8Fuel delivery pipe mounting screw 3.5 0.35Fuel pump mounting bolt 10 1.0TPS and STPS mounting screw 3.5 0.35COOLING SYSTEMITEM N·m kgf-mImpeller securing bolt 8 0.8Water pump cover screw 5 0.5Water pump mounting bolt 10 1.0ECT sensor 18 1.8Thermostat cover bolt 10 1.0Cooling fan/horn mounting bolt 8 0.8Thermostat air bleeding bolt 5.5 0.55
SERVICING INFORMATION 10-39CHASSISITEM N·m kgf-mSteering stem head nut 90 9.0Steering stem lock-nut 80 8.0Front fork upper clamp bolt 23 2.3Front fork lower clamp bolt 23 2.3Front fork cap bolt 23 2.3Front fork cylinder bolt 30 3.0Front axle 100 10.0Front axle pinch bolt 23 2.3Handlebar clamp bolt 23 2.3Front brake master cylinder mounting bolt 10 1.0Front brake caliper mounting bolt 25 2.5Front brake caliper housing bolt 22 2.2Front brake pad mounting pin 16 1.6Brake hose union bolt 23 2.3Clutch lever holder bolt 10 1.0Air bleeder valve (Front and Rear) 7.5 0.75Brake disc bolt (Front and Rear) 23 2.3Rear brake caliper mounting bolt 18 1.8Rear brake caliper sliding pin 33 3.3Rear brake pad mounting pin 16 1.6Rear brake master cylinder mounting bolt 10 1.0Rear brake master cylinder rod locknut 18 1.8Front footrest bracket mounting bolt 23 2.3Swingarm pivot shaft 15 1.5Swingarm pivot nut 100 10.0Swingarm pivot locknut 90 9.0Cushion lever mounting nut 132 13.2Cushion rod nut 78 7.8Rear shock absorber mounting nut (Upper and Lower) 50 5.0Rear axle nut 100 10.0Rear sprocket nut 60 6.0Side-stand mounting bracket bolt 50 5.0
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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
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8-70 CHASSIS• Remove the front fo
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8-72 CHASSIS• Rout the rear brake
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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
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
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 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
Page 464 and 465: 10-48 SERVICING INFORMATIONTIRECold
Page 466 and 467: EMISSION CONTROL INFORMATION 11-1EM
Page 468 and 469: EMISSION CONTROL INFORMATION 11-3CR
Page 470 and 471: EMISSION CONTROL INFORMATION 11-5NO
Page 472 and 473: EMISSION CONTROL INFORMATION 11-7PA
Page 474 and 475: EMISSION CONTROL INFORMATION 11-9HE
Page 476 and 477: Prepared byOctober, 2005Part No. 99
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