general information - Martin Nez

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10-46 SERVICING INFORMATIONTHROTTLE BODYITEMBore sizeI.D. No.Idle r/min.Fast idle r/min.Throttle cable playSPECIFICATION38 mm44G01 300 ± 100 r/min.1 500 – 2 000 r/min. When cold engine2.0 – 4.0 mmELECTRICALUnit: mmITEM SPECIFICATION NOTEFiring order 1.2.4.3Spark plugNGK: CR9ETypeDENSO: U27ESR-NGap 0.7 – 0.8Spark performanceOver 8 at 1 atm.CKP sensor resistance142 – 194 ΩCKP sensor peak voltage0.5 V and moreIgnition coil resistanceTerminal –Primary1.3 – 1.9 ΩTerminalSecondary10.8 – 16.2 kΩPlug cap –TerminalIgnition coil primary peak voltage85 V and moreGenerator coil resistance0.2 – 0.9 ΩGenerator no-load performance(When engine is cold)65 V and more at 5 000 r/min.Starter motor brush length 10 6.5Regulated voltage (charging output)14.0 – 15.5 V at 5 000 r/min.Starter relay resistance3 – 6 ΩGP switch voltage0.6 V and more (From 1st to top without neutral)BatteryType designationFTX9-BSCapacity12 V 28.8 kC (8 Ah)/10 HRFuse sizeHI10 AHeadlightLO10 AIgnition15 ASignal10 AFuel10 AFan15 AMain30 A
SERVICING INFORMATION 10-47WATTAGEITEMSTANDARD/SPECIFICATIONHeadlight HI 60LO 55Position light 5 × 2Brake light/TaillightLEDTurn signal light 10 × 4License plate light 5Speedometer lightLEDTachometer lightLEDNeutral indicator lightLEDHigh beam indicator lightLEDTurn signal indicator lightLEDOil pressure/Engine coolant temp. warning indicator lightLEDFI warning indicator lightLEDImmobilizer indicator lightLEDUnit: WBRAKE + WHEELUnit: mmITEM STANDARD LIMITRear brake pedal height 45 – 55 ----Brake disc thickness Front 4.8 – 5.2 4.5Rear 4.8 – 5.2 4.5Brake disc runout ---- 0.30Master cylinder bore Front 15.870 – 15.913 ----Rear 14.000 – 14.043 ----Master cylinder piston diam Front 15.827 – 15.854 ----Rear 13.957 – 13.984 ----Brake caliper cylinder bore Front 30.230 – 30.306 / 33.960 – 34.036 ----Rear 38.180 – 38.256 ----Brake caliper piston diam Front 30.150 – 30.200 / 33.884 – 33.934 ----Rear 38.098 – 38.148 ----Brake fluid type DOT 4 ----Wheel rim runout Axial ---- 2.0Radial ---- 2.0Wheel rim size Front 17 M/C × MT 3.50 ----Rear 17 M/C × MT 5.50 ----Wheel axle runout Front ---- 0.25Rear ---- 0.25
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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
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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
Page 412 and 413: 9-38 ELECTRICAL SYSTEMIGNITION SWIT
Page 414 and 415: 9-40 ELECTRICAL SYSTEMBATTERYSPECIF
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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 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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