general information - Martin Nez

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PERIODIC MAINTENANCE 2-35Data of intake negative pressure during idling (100 °C)Check the manifoldabsolute pressure.Approx. XXX mmHgData of secondary throttle valve operation at the time of startingCloses fully in approx. XX sec.
ENGINE 3-1ENGINECONTENTSENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ............3- 2ENGINE REMOVAL AND INSTALLATION...................................................3- 3ENGINE REMOVAL ................................................................................3- 3ENGINE INSTALLATION........................................................................3- 9ENGINE DISASSEMBLY...............................................................................3-14ENGINE COMPONENTS INSPECTIONAND SERVICE...............................................................................................3-27CYLINDER HEAD COVER......................................................................3-27CMP SENSOR.........................................................................................3-27PAIR REED VALVE ................................................................................3-27PCV HOSE ..............................................................................................3-28CAMSHAFT.............................................................................................3-28CAM CHAIN TENSION ADJUSTER .......................................................3-30CAM CHAIN TENSIONER ......................................................................3-31CAM CHAIN GUIDE ................................................................................3-31CYLINDER HEAD AND VALVE..............................................................3-31CLUTCH ..................................................................................................3-40OIL PUMP................................................................................................3-41STARTER CLUTCH ................................................................................3-41GENERATOR ..........................................................................................3-42WATER PUMP ........................................................................................3-43GEARSHIFT SYSTEM ............................................................................3-43OIL PRESSURE REGULATOR ..............................................................3-44OIL STRAINER........................................................................................3-44TRANSMISSION .....................................................................................3-45CYLINDER...............................................................................................3-48PISTON AND PISTON RING ..................................................................3-49CRANKCASE ..........................................................................................3-51CRANKSHAFT AND CONROD ..............................................................3-58CRANKSHAFT JOURNAL BEARING ....................................................3-62CRANKSHAFT THRUST BEARING.......................................................3-65ENGINE REASSEMBLY................................................................................3-673
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 and 46: 2-28 PERIODIC MAINTENANCEEXHAUST PI
Page 47 and 48: 2-30 PERIODIC MAINTENANCE
Page 49 and 50: 2-32 PERIODIC MAINTENANCEOIL PRESSU
Page 51: 2-34 PERIODIC MAINTENANCEData at 3
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
Page 99 and 100: ENGINE 3-47TRANSMISSION PARTS LOCAT
Page 101 and 102: ENGINE 3-49PISTON AND PISTON RINGPI
Page 103 and 104:
ENGINE 3-51CRANKCASEGEARSHIFT FORK
Page 105 and 106:
ENGINE 3-53• Remove the oil seal
Page 107 and 108:
ENGINE 3-55OIL JETRemoval• Remove
Page 109 and 110:
ENGINE 3-57• Remove the water jac
Page 111 and 112:
ENGINE 3-59CONROD BIG END SIDE CLEA
Page 113 and 114:
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
Page 119 and 120:
ENGINE 3-67ENGINE REASSEMBLY• Rea
Page 121 and 122:
ENGINE 3-69• Install the pistons
Page 123 and 124:
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
Page 135 and 136:
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
Page 143 and 144:
ENGINE 3-91• Install the pressure
Page 145 and 146:
ENGINE 3-93• Apply SUZUKI SUPER G
Page 147 and 148:
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
Page 153 and 154:
ENGINE 3-101• Tighten the head co
Page 155 and 156:
4-2 FI SYSTEM DIAGNOSISFI SYSTEM DI
Page 157 and 158:
4-4 FI SYSTEM DIAGNOSIS• When con
Page 159 and 160:
4-6 FI SYSTEM DIAGNOSISELECTRICAL C
Page 161 and 162:
4-8 FI SYSTEM DIAGNOSISSHORT CIRCUI
Page 163 and 164:
4-10 FI SYSTEM DIAGNOSISFI SYSTEM T
Page 165 and 166:
4-12 FI SYSTEM DIAGNOSISFI SYSTEM P
Page 167 and 168:
4-14 FI SYSTEM DIAGNOSISFI SYSTEM W
Page 169 and 170:
4-16 FI SYSTEM DIAGNOSISSELF-DIAGNO
Page 171 and 172:
4-18 FI SYSTEM DIAGNOSISCODE MALFUN
Page 173 and 174:
4-20 FI SYSTEM DIAGNOSISFAIL-SAFE F
Page 175 and 176:
4-22 FI SYSTEM DIAGNOSISFI SYSTEM T
Page 177 and 178:
4-24 FI SYSTEM DIAGNOSISSELF-DIAGNO
Page 179 and 180:
4-26 FI SYSTEM DIAGNOSISUSE OF SDS
Page 181 and 182:
4-28 FI SYSTEM DIAGNOSISMALFUNCTION
Page 183 and 184:
4-30 FI SYSTEM DIAGNOSISDTC No.C29P
Page 185 and 186:
4-32 FI SYSTEM DIAGNOSIS“C11” (
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
4-38 FI SYSTEM DIAGNOSIS6) Disconne
Page 193 and 194:
4-40 FI SYSTEM DIAGNOSISStep 31) Tu
Page 195 and 196:
Page 197 and 198:
4-44 FI SYSTEM DIAGNOSISStep 1 (Whe
Page 199 and 200:
4-46 FI SYSTEM DIAGNOSISAre the con
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
Page 209 and 210:
Page 211 and 212:
Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
4-66 FI SYSTEM DIAGNOSISACTIVE CONT
Page 221 and 222:
4-68 FI SYSTEM DIAGNOSIS STP sensor
Page 223 and 224:
Page 225 and 226:
Page 227 and 228:
Page 229 and 230:
M4-76 FI SYSTEM DIAGNOSIS“C41”
Page 231 and 232:
Page 233 and 234:
4-80 FI SYSTEM DIAGNOSIS6) Remove t
Page 235 and 236:
Page 237 and 238:
Page 239 and 240:
4-86 FI SYSTEM DIAGNOSISACTIVE CONT
Page 241 and 242:
4-88 FI SYSTEM DIAGNOSISECT SENSOR
Page 243 and 244:
4-90 FI SYSTEM DIAGNOSISHO2 SENSOR
Page 245 and 246:
5-2 FUEL SYSTEM AND THROTTLE BODYFU
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
5-8 FUEL SYSTEM AND THROTTLE BODYRE
Page 253 and 254:
5-10 FUEL SYSTEM AND THROTTLE BODY
Page 255 and 256:
5-12 FUEL SYSTEM AND THROTTLE BODYT
Page 257:
5-14 FUEL SYSTEM AND THROTTLE BODY
Page 260 and 261:
FUEL SYSTEM AND THROTTLE BODY 5-17T
Page 262 and 263:
FUEL SYSTEM AND THROTTLE BODY 5-19T
Page 264 and 265:
FUEL SYSTEM AND THROTTLE BODY 5-21F
Page 266 and 267:
FUEL SYSTEM AND THROTTLE BODY 5-23
Page 268 and 269:
FUEL SYSTEM AND THROTTLE BODY 5-25S
Page 270 and 271:
6-2 EXHAUST SYSTEMPRECAUTIONS FOR E
Page 272 and 273:
6-4 EXHAUST SYSTEM• Remove the mu
Page 274 and 275:
COOLING AND LUBRICATION SYSTEM 7-1C
Page 276 and 277:
COOLING AND LUBRICATION SYSTEM 7-3C
Page 278 and 279:
COOLING AND LUBRICATION SYSTEM 7-5R
Page 280 and 281:
COOLING AND LUBRICATION SYSTEM 7-7E
Page 282 and 283:
COOLING AND LUBRICATION SYSTEM 7-9T
Page 284 and 285:
COOLING AND LUBRICATION SYSTEM 7-11
Page 286 and 287:
Page 288 and 289:
Page 290 and 291:
Page 292 and 293:
Page 294 and 295:
Page 296 and 297:
8-2 CHASSISCHASSISCONTENTSREAR SUSP
Page 298 and 299:
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
Page 314 and 315:
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
Page 322 and 323:
8-28 CHASSISREMOVAL• Remove the f
Page 324 and 325:
8-30 CHASSISAfter installing the ha
Page 326 and 327:
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
Page 338 and 339:
8-44 CHASSISREMOVAL• Remove the s
Page 340 and 341:
8-46 CHASSISINSPECTION AND DISASSEM
Page 342 and 343:
8-48 CHASSISPLATE• Inspect the pl
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
Page 356 and 357:
8-62 CHASSISMASTER CYLINDER REASSEM
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 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 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 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
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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