general information - Martin Nez

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PERIODIC MAINTENANCE 2-29CHASSIS BOLTS AND NUTSTighten initially at 1 000 km (2 months) and every6 000 km (12 months) thereafter.Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-30 for the locationsof the following nuts and bolts on the motorcycle.)Item N·m kgf-m1 Steering stem head nut 90 9.02 Steering stem lock-nut 80 8.03 Front fork upper clamp bolt 23 2.34 Front fork lower clamp bolt 23 2.35 Front fork cap bolt 23 2.36 Front axle 100 10.07 Front axle pinch bolt 23 2.38 Handlebar clamp bolt 23 2.39 Front brake master cylinder mounting bolt 10 1.00 Front brake caliper mounting bolt 25 2.5A Front brake caliper housing bolt 22 2.2B Front brake pad mounting pin 16 1.6C Brake hose union bolt 23 2.3D Air bleeder valve 7.5 0.75E Brake disc bolt 23 2.3F Rear brake caliper mounting bolt 18 1.8G Rear brake caliper sliding pin 33 3.3H Rear brake pad mounting pin 16 1.6I Rear brake master cylinder mounting bolt 10 1.0J Rear brake master cylinder rod lock-nut 18 1.8K Front footrest bracket mounting bolt 23 2.3L Swingarm pivot shaft 15 1.5M Swingarm pivot nut 100 10.0N Swingarm pivot lock-nut 90 9.0O Rear shock absorber mounting bolt/nut (Upper & Lower) 50 5.0P Cushion rod nut 78 7.8Q Cushion lever mounting nut 132 13.2R Rear axle nut 100 10.0S Rear sprocket nut 60 6.0
2-30 PERIODIC MAINTENANCE
Page 1 and 2: GSR60099500-36160-01E
Page 3: HOW TO USE THIS MANUALTO LOCATE WHA
Page 6 and 7: MMAL-CodeMaxMILMinNNOXOOHCOPSPPCVRS
Page 8: GENERAL INFORMATION 1-1GENERAL INFO
Page 11 and 12: 1-4 GENERAL INFORMATIONSUZUKI GSR60
Page 13 and 14: 1-6 GENERAL INFORMATIONENGINE COOLA
Page 15 and 16: 1-8 GENERAL INFORMATIONINFORMATION
Page 17 and 18: 1-10 GENERAL INFORMATIONCHASSISFron
Page 19 and 20: 2-2 PERIODIC MAINTENANCEPERIODIC MA
Page 21 and 22: 2-4 PERIODIC MAINTENANCEMAINTENANCE
Page 23 and 24: 2-6 PERIODIC MAINTENANCESPARK PLUG
Page 25 and 26: 2-8 PERIODIC MAINTENANCE• Remove
Page 27 and 28: 2-10 PERIODIC MAINTENANCENOTE:* Be
Page 29 and 30: 2-12 PERIODIC MAINTENANCE(EXHAUST S
Page 31 and 32: 2-14 PERIODIC MAINTENANCEOIL FILTER
Page 33 and 34: 2-16 PERIODIC MAINTENANCECLUTCHInsp
Page 35 and 36: 2-18 PERIODIC MAINTENANCEAIR BLEEDI
Page 37 and 38: 2-20 PERIODIC MAINTENANCE• Count
Page 39 and 40: 2-22 PERIODIC MAINTENANCEBRAKE(BRAK
Page 41 and 42: 2-24 PERIODIC MAINTENANCEBRAKE LIGH
Page 43 and 44: 2-26 PERIODIC MAINTENANCETIRESInspe
Page 45: 2-28 PERIODIC MAINTENANCEEXHAUST PI
Page 49 and 50: 2-32 PERIODIC MAINTENANCEOIL PRESSU
Page 51 and 52: 2-34 PERIODIC MAINTENANCEData at 3
Page 53 and 54: ENGINE 3-1ENGINECONTENTSENGINE COMP
Page 55 and 56: ENGINE 3-3ENGINE REMOVAL AND INSTAL
Page 57 and 58: ENGINE 3-5• Remove the front engi
Page 59 and 60: ENGINE 3-7ENGINE SPROCKET AND GEAR
Page 61 and 62: ENGINE 3-9• Remove the engine mou
Page 63 and 64: ENGINE 3-11• Tighten all engine m
Page 65 and 66: ENGINE 3-13• Replace the exhaust
Page 67 and 68: ENGINE 3-15CAMSHAFTS• Remove the
Page 69 and 70: ENGINE 3-17CLUTCH• Remove the clu
Page 71 and 72: ENGINE 3-19• Remove the thrust wa
Page 73 and 74: ENGINE 3-21• Remove the starter c
Page 75 and 76: ENGINE 3-23GEAR POSITION SWITCH•
Page 77 and 78: ENGINE 3-25MIDDLE CRANKCASE• Remo
Page 79 and 80: ENGINE 3-27ENGINE COMPONENTS INSPEC
Page 81 and 82: ENGINE 3-29CAMSHAFT JOURNAL WEAR•
Page 83 and 84: ENGINE 3-31CAM CHAIN TENSIONERINSPE
Page 85 and 86: ENGINE 3-33VALVE STEM RUNOUT• Sup
Page 87 and 88: ENGINE 3-35• Cool down the new va
Page 89 and 90: ENGINE 3-37• Clean and assemble t
Page 91 and 92: ENGINE 3-39INTAKE PIPE• Remove th
Page 93 and 94: ENGINE 3-41CLUTCH BEARING INSPECTIO
Page 95 and 96: ENGINE 3-43WATER PUMPDISASSEMBLY/IN
Page 97 and 98:
ENGINE 3-45TRANSMISSIONDISASSEMBLYD
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ENGINE 3-47TRANSMISSION PARTS LOCAT
Page 101 and 102:
ENGINE 3-49PISTON AND PISTON RINGPI
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ENGINE 3-51CRANKCASEGEARSHIFT FORK
Page 105 and 106:
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
Page 111 and 112:
ENGINE 3-59CONROD BIG END SIDE CLEA
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ENGINE 3-61 Crank pin O.D.CodeO.D.
Page 115 and 116:
ENGINE 3-63• Check the correspond
Page 117 and 118:
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
Page 125 and 126:
ENGINE 3-73• Install the regulato
Page 127 and 128:
ENGINE 3-75• Apply SUZUKI BOND to
Page 129 and 130:
ENGINE 3-77OIL STRAINER• Install
Page 131 and 132:
ENGINE 3-79CRANKCASE BREATHER COVER
Page 133 and 134:
ENGINE 3-81• Apply SUZUKI BOND to
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ENGINE 3-83CAM CHAIN DRIVE SPROCKET
Page 137 and 138:
ENGINE 3-85• Install the starter
Page 139 and 140:
ENGINE 3-87OIL PUMP• Install the
Page 141 and 142:
ENGINE 3-89• Lock the clutch slee
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ENGINE 3-91• Install the pressure
Page 145 and 146:
ENGINE 3-93• Apply SUZUKI SUPER G
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ENGINE 3-95• Pull the cam chain l
Page 149 and 150:
ENGINE 3-97• Tighten the camshaft
Page 151 and 152:
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
Page 272 and 273:
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
Page 280 and 281:
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
Page 300 and 301:
8-6 CHASSISFRONT WHEELCONSTRUCTION1
Page 302 and 303:
8-8 CHASSISINSPECTION AND DISASSEMB
Page 304 and 305:
8-10 CHASSISREASSEMBLY AND INSTALLA
Page 306 and 307:
8-12 CHASSISWHEELInstall the front
Page 308 and 309:
8-14 CHASSISREMOVAL AND DISASSEMBLY
Page 310 and 311:
8-16 CHASSIS• Remove the cylinder
Page 312 and 313:
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
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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
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
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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
Page 348 and 349:
8-54 CHASSIS* This brake system is
Page 350 and 351:
8-56 CHASSISCALIPER REMOVAL• Remo
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8-58 CHASSISPISTON SEAL• Install
Page 354 and 355:
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
Page 362 and 363:
8-68 CHASSISCALIPER INSPECTIONBRAKE
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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
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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
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9-38 ELECTRICAL SYSTEMIGNITION SWIT
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9-40 ELECTRICAL SYSTEMBATTERYSPECIF
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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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