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Suzuki Manuals
Motorcycle
2001 GSX-R1000
Service manual
Table Of Contents - Suzuki 2001 GSX-R1000 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Foreword
3
Group Index
3
How To Use This Manual
4
To Locate What You Are Looking For
4
Component Parts And Work To Be Done
4
Symbol (For Usa)
5
Symbol (For The Other Countries)
6
Abbreviations Used In This Manual
7
Sae-To-Former Suzuki Term (Only For Usa)
9
General Information
11
Contents
11
Warning/Caution/Note
12
General Precautions
12
Suzuki Gsx-R1000K1 (2001-Model) View
14
Serial Number Location
14
Fuel, Oil And Engine Coolant Recommendation
15
Engine Oil
15
Brake Fluid
15
Front Fork Oil
15
Anti-Freeze/Engine Coolant
16
Liquid Amount Of Water/Engine Coolant
16
Break-In Procedures
16
Cylinder Identification
16
Information Labels
17
Specifications
18
Dimensions And Dry Mass
18
Capacities
19
Electrical
19
Country And Area Codes
20
Periodic Maintenance
21
Periodic Maintenance Schedule
22
Periodic Maintenance Chart
22
Lubrication Points
23
Maintenance And Tune-Up Procedures
24
Air Cleaner
24
Heat Range
25
Carbon Deposits
25
Spark Plug Gap
26
Electrode's Condition
26
Spark Plug And Ignition Coil/Plug Cap Installation
26
Valve Clearance
27
Valve Clearance Adjustment
29
Intake Side
30
Exhaust Side
31
Engine Oil And Oil Filter
32
Engine Oil Replacement
32
Oil Filter Replacement
33
Exhaust Control Valve
33
Fuel Hose
34
Engine Idle Speed
34
Throttle Cable Play
35
Minor Adjustment
35
Major Adjustment
36
Clutch
36
Cooling System
37
Engine Coolant Level Check
37
Engine Coolant Change
37
Air Bleeding The Cooling Circuit
38
Radiator Hoses
38
Drive Chain
39
Checking
39
Adjusting
40
Cleaning And Lubricating
40
Brake Fluid Level Check
41
Brake Pads
41
Front Brake
41
Rear Brake
42
Brake Pedal Height
42
Brake Light Switch
42
Air Bleeding From Brake Fluid Circuit
43
Tire Tread Condition
44
Steering
45
Front Fork
45
Rear Suspension
45
Exhaust Pipe Bolt And Nut
46
Chassis Bolts And Nuts
47
Compression Pressure Check
49
Compression Test Procedure
49
Low Oil Pressure
50
High Oil Pressure
50
Oil Pressure Test Procedure
50
Engine
51
Engine Components Removable With The Engine In Place
52
Engine Center
52
Engine Right Side
52
Engine Left Side
52
Engine Removal
53
Oil Cooler
54
Radiator
54
Exhaust Pipe And Muffler
56
Electric Parts
56
Engine Sprocket And Gear Shift Lever
58
Engine Mounting
59
Engine Installation
61
Engine Disassembly
65
Starter Motor
65
Pair Valve
65
Cylinder Head Cover
65
Camshafts
66
Cylinder Head
67
Oil Pump
70
Gear Shift System
70
Starter Idle Gear
71
Starter Clutch
72
Cam Chain, Cam Chain Tensioner, Cam Chain Guide
72
Ckp Sensor Inspection
72
Generator Cover
73
Generator Rotor
73
Gear Position Switch
74
Breather Cover
74
Oil Filter
74
Oil Pan
74
Oil Pressure Regulator
75
Oil Pressure Switch
75
Oil Strainer
75
Lower Crank Case
75
Middle Crankcase
76
Balancer Shaft
76
Crankshaft
76
Piston And Conrod
77
Engine Components Inspection And Service
78
Pair Reed Valve
78
Pair Control Valve
78
Cam Position Sensor
79
Camshaft Identification
79
Cam Wear
79
Camshaft Journal Wear
80
Camshaft Runout
81
Cam Sprocket
81
Cam Chain Tension Adjuster
81
Cam Chain Guide
81
Cylinder Head And Valve
82
Valve And Valve Spring Disassembly
82
Cylinder Head Distortion
83
Valve Stem Runout
83
Valve Head Radial Runout
83
Valve Face Wear
83
Valve Stem Deflection
84
Valve Stem Wear
84
Valve Guide Servicing
85
Valve Seat Width Inspection
86
Valve Seat Servicing
86
Initial Seat Cut
87
Top Narrowing Cut
87
Botton Harrowing Cut
87
Final Seat Cut
88
Valve Stem End Condition
89
Valve Spring
89
Valve And Valve Spring Reassembly
90
Intake Pipe
91
Water Bypass Union
91
Clutch Drive Plates Inspection
92
Clutch Driven Plates Inspection
92
Clutch Spring Inspection
92
Clutch Bearing Inspection
92
Inspection
93
Gearshift System
94
Gearshift Shaft/Gearshift Arm Disassembly
94
Gearshift Shaft/Gearshift Arm Reassembly
94
Transmission
96
Reassembly
97
Transmission Parts Location
98
Cylinder Distortion
99
Cylinder Bore
99
Piston And Piston Ring
100
Piston Diameter
100
Piston To Cylinder Clearance
100
Pinton Pins And Pin Bore
100
Piston Ring To Groove Clearance
101
Piston Ring Free End Gap And Piston Ring End Gap
101
Piston Ring Reassembly
102
Lower Crankcase
103
Gearshift Fork And Gearshift Cam
103
Gearshift Fork To Groove Clearance
103
Gearshift Fork Groove Width
103
Bearing Removal
104
Installation
105
Oil Jet
107
Removal
107
Inspection And Cleaning
107
Plugs
108
Balancer Shaft Journal Bearing
109
Selection
109
Crankshaft Runout
111
Conrod Small End I.d.
111
Conrod Big End Side Clearance
111
Conrod-Crank Pin Bearing Inspection
112
Conrod-Crank Pin Bearing Selection
112
Crankshaft Journal Bearing
114
Crankshaft Thrust Bearing
116
Crankshaft Thrust Clearance Adjustment
116
Thrust Bearing Selection Table
117
Engine Reassembly
118
Crankcase
121
Cam Chain Drive Sprocket
132
Cam Chain Tensioner And Cam Chain Guide
132
Started Idle Gear
133
Fi System/Intake Air System/Exhaust System
150
Precautions In Servicing
152
Connector/Coupler
152
Fuse
153
Ecm/Various Sensors
153
Electrical Circuit Inspection Procedure
154
Open Circuit Heck
154
Continuity Check
155
Voltage Check
156
Short Circuit Check (Wire Harness To Ground)
156
Using Testers
157
Fi System Technical Feature
158
Injection Time (Injection Volume)
158
Compensation Of Injection Time (Volume)
159
Injection Stop Control
159
Fuel Delivery System
160
Fuel Pump
161
Fuel Pressure Regulator
162
Fuel Injector
162
Fuel Pump Control System
163
Ecm (Fi Control Unit)
164
Injection Timing
165
Intake Air Pressure Sensor (Iap Sensor)
166
Throttle Position Sensor (Tp Sensor)
166
Crankshaft Position Sensor (Ckp Sensor)
167
Camshaft Position Sensor (Cmp Sensor)
167
Intake Air Temperature Sensor (Iat Sensor)
167
Engine Coolant Temperature Sensor (Ect Sensor)
168
Atmospheric Pressure Sensor (Ap Sensor)
168
Tip Oven Sensor (To Sensor)
169
Secondary Throttle Position Sensor (Stp Sensor)
169
Intake Air System
170
Secondary Throttle Control System
170
Operation
171
Exhaust Control System
172
Fi System Parts Location
174
Fi System Diagram
176
Fi System Wiring Diagram
177
Self-Diagnosis Function
178
User Mode
178
Dealer Mode
179
Fail-Safe Function
181
Fi System Troubleshooting
182
Self-Diagnostic Procedure
183
Self-Diagnosis Reset Procedure
183
Malfunction Code And Defective Condition
184
"C12" Cmp Sensor Circuit Malfunction
186
"C12" Ckp Sensor Circuit Malfunction
187
"C13" Iap Sensor Circuit Malfunction
188
Output Voltage
189
"C14" Tp Sensor Circuit Malfunction
190
"C15" Ect Sensor Circuit Malfunction
192
"C21" Iat Sensor Circuit Malfunction
193
"C22" Ap Sensor Circuit Malfunction
194
"C23" To Sensor Circuit Malfunction
196
"C24", "C25", "C26" Or "C27" Ignition System Malfunction
197
"C28" Stv Actuatoor Circuit Malfunction
197
"C29" Stp Sensor Circuit Malfunction
198
"C31" Gear Position (Gp) Switch Circuit Malfunction
200
"C32", "C33", "C34" Or "C35" Fuel Injector Malfunction
201
"C41" Fp Relay Circuit Malfunction
202
"C42" Ig Switch Circuit Malfunction
202
"C46" Excv Actuator Circuit Malfunction
203
Fuel System
206
Fuel Tank Lift-Up
206
Fuel Tank Removal
206
Fuel Tank Installation
206
Fuel Pressure Inspection
207
Fuel Pump Inspection
208
Fuel Discharge Amount Inspection
208
Fuel Pump Relay Inspection
210
Fuel Pump And Fuel Filter Removal Construction
210
Fuel Mesh Filter Inspection And Cleaning
212
Fuel Pump And Fuel Mesh Filter Installation
212
Throttle Body Construction
215
Air Cleaner Box
216
Throttle Body
217
Throttle Body Disassembly
218
Throttle Body Cleaning
219
Throttle Body Reassembly
220
Wire Color
221
Throttle Body Installation
222
Stp Sensor Adjustment
223
Throttle Body Clamp Position
223
Fuel Injector Inspection
224
Fuel Injector Removal
224
Fuel Injector Installation
224
Fast Idle Adjustment
224
Throttle Valve Synchronization
225
Calibrating Each Gauge
225
Throttle Position Sensor (Tps) Setting
228
Throttle Cable Adjustment
228
Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)
229
Excva Removal
229
Excva Installation
230
Excv Cable Replacement
231
Excva Adjustment
233
Excv Removal
236
Excv Inspection
236
Excv Installation
237
Iap Sensor Inspection/Removal/Installation
239
Tp Sensor Inspection/Removal/Installation
239
Cmp Sensor Inspection/Removal/Installation
239
Iat Sensor Inspection/Removal/Installation
239
Ect Sensor Inspection/Removal/Installation
240
Ap Sensor Inspection/Removal/Installation
240
To Sensor Inspection/Removal/Installation
240
Stp Sensor Inspection/Removal/Installation
240
Cooling And Lubrication System
241
Engine Coolant
242
Cooling Circuit Inspection
243
Radiator And Water Hoses
244
Radiator Removal
244
Radiator Cap Inspection
244
Radiator Inspection And Cleaning
244
Radiator Remounting
245
Water Hose Inspection
245
Cooling Fan
246
Cooling Fan Thermo-Switch
246
Cooling Fan Control Relay
247
Engine Coolant Temperature Sensor
248
Temperature Sensor Specification
248
Thermostat
249
Water Pump
251
Removal And Disassembly
251
Bearing
254
Mechanical Seal
254
Oil Seal
254
Seal Washer
254
Reassembly And Installation
255
Lubrication System
258
Engine Lubrication System Chart
260
Engine Lubrication System
261
Chassis
264
Exterior Parts
266
Fastener Removal And Reinstallation
266
Screen
266
Body Cowling Cover And Lower Bracket Cover
267
Right And Left Under Cowlings
267
Body Cowling
268
Remounting
268
Right And Left Air Intake Pipes
269
Cowling Brace
269
Front Seat
270
Rear Seat And Seat Tail Cover
270
Frame Cover
270
Front Wheel Construction
271
Axle Shaft
273
Wheel Bearings
273
Reassembly And Remounting
274
Brake Disc
275
Spacer Nut
276
Brake Caliper
276
Front Axle
276
Front Fork Construction
277
Inner And Outer Tubes
280
Fork Spring
280
Damper Rod
281
Oil Seal And Dust Seal
281
Damper Rod Bolt
282
Fork Oil
283
Front Fork Inner Rod Lock Nut
284
Front Fork Cap Bolt
284
Suspension Settings
286
Spring Pre-Load Adjustment
286
Damping Force Adjustment
286
Standard Front Suspension Setting
286
Steering Damper Construction
287
Steering Construction
288
Outer Race
290
Inner Race
290
Stem Nut
291
Front Fork And Steering Stem Upper Bracket
292
Steering Tension Adjustment
292
Handlebar Construction
293
Right Handlebar
293
Left Handlebar
293
Rear Wheel Construction
296
Rear Axle
298
Wheel Damper
298
Sprocket
298
Bearings
299
Dust Seals
302
Rear Shock Absorber Construction
304
Rear Shock Absorber Disposal
306
Gas Pressure Release
306
Suspension Setting
307
Damping Force Adjustment (Rebound Side, Compression Side)
307
Standard Suspension Setting
307
Rear Suspension Construction
308
Spacer
311
Swingarm Bearing
311
Cushion Lever Bearing
312
Cushion Lever And Cushion Lever Rods
312
Swingarm Pivot Shaft
312
Chain Buffer
312
Swingarm Pivot Thrust Clearance Adjustment
315
Shock Absorber And Cushion Lever Mounting Nut
316
Torque Link
316
Final Inspection And Adjustment
316
Front Brake Construction
317
Brake Pad Replacement
318
Brake Fluid Replacement
318
Caliper Removal And Disassembly
319
Caliper Inspection
320
Caliper Reassembly And Remounting
320
Piston Seal
320
O-Ring
320
Brake Disc Inspection
321
Master Cylinder Removal And Disassembly
322
Master Cylinder Inspection
323
Master Cylinder Reassembly And Remounting
323
Rear Brake Construction
325
Cylinder, Piston And Cup Set
330
Tire Removal
331
Wheel Inspection
331
Tire Inspection
331
Valve Inspection
332
Valve Installation
332
Tire Installation
332
Balancer Weight
333
Drive Chain Cutting
334
Drive Chain Connecting
335
Joint Plate Installation
335
Joint Pin Staking
336
Electrical System
339
Cautions In Servicing
340
Connector
340
Coupler
340
Clamp
340
Connecting The Battery
341
Wiring Procedure
341
Using The Multi Circuit Tester
341
Location Of Electrical Components
342
Charging System
344
Battery Current Leakage
345
Regulated Voltage
346
Generator Coil Resistance
346
Generator No-Load Performace
346
Regulator/Rectifier
347
Starter System And Side-Stand/Ignition Interlock System
348
Starter Motor Removal And Disassembly
349
Starter Motor Inspection
350
Commutator
350
Armature Coil Inspection
350
Starter Motor Reassembly
350
Starter Relay Inspection
351
Side Stand/Ignition Interlock System Parts Inspection
352
Side-Stand Switch
352
Turn Signal/Side-Stand Relay
354
Side-Stand Relay Inspection
354
Diode Inspection
354
Ignition System
355
Ignition Coil Primary Peak Voltage
357
Ignition Coil/Plug Cap Resistance
358
Ckp Sensor Peak Voltage
359
Ckp Sensor Resistance
360
Combination Meter
361
Led (Light Emitting Diode)
361
Stepping Motor
363
Engine Coolant Temperature Meter And Indicator
364
Fuel Level Indicator Switch Inspection
365
Fuel Level Indicator Light Inspection
365
Fuel Level Resistor Inspection
365
Speedometer Sensor
366
Oil Pressure Indicator
366
Lamps
367
Headlight, Brake Light/Taillight And Turn Signal Light
367
Headlight Beam Adjustment
367
Relays
368
Ignition Switch Removal
368
Battery Specifications
370
Initial Charging
370
Filling Electrolyte
370
Servicing
371
Recharging Operation
372
Servicing Information
373
Troubleshooting
374
Fi System Malfunction Code And Defective Condition
374
Radiator (Cooling System)
381
Brakes
383
Battery
385
Wiring Harness Routing
386
Inside Of The Body Cowling
386
Cable Routing
389
Fuel Tank Drain Hose Routing
390
Cooling System Hose Routing
391
Front Brake Hose Routing
392
Rear Brake Hose Routing
393
Pair (Air Supply) System Hose Routing
394
Fuel Tank Set-Up
395
Cowling Set-Up
396
Frame Cover Set-Up
397
Heat Shield Set-Up
397
Side-Stand Set-Up
398
Gearshift Pedal Set-Up
398
Seat Lock Cable Routing
399
Front Fender Set-Up
399
Special Tools
400
Tightening Torque
403
Fi System And Intake Air System
404
Tightening Torque Chart
406
Service Data
407
Valve + Guide
407
Camshaft + Cylinder Head
407
Cylinder + Piston + Piston Ring
408
Conrod + Crankshaft
409
Balancer
409
Transmission + Drive Chain
410
Thermostat + Radiator + Fan + Coolant
410
Injector + Fuel Pump + Fuel Pressure Regulator
411
Fi Sensors + Secondary Throttle Valve Actuator
411
Wattage
413
Brake + Wheel
413
Tire
414
Suspension
414
Fuel + Oil
415
Emission Control Information
417
Fuel Injection System
418
Evaporative Emission Control System (Only For E-33)
418
Canister Hose Routing (Only For E-33)
419
Canister
420
Tank Pressure Control Valve
420
Pair (Air Supply) System Diagram
421
Pair (Air Supply) System Inspecting
423
Gsx-R1000K2 ('02-Model)
424
Drive Train
429
Tightening Torque For Cam Chain Tension Adjuster Cap
435
Fuel Pump And Fuel Level Indicator Switch
436
Fast Idle
437
Wiring Diagram ('01) For E-03, 28, 33
439
Wiring Diagram ('01) For E-19
440
Wiring Diagram ('01) For E-24
441
Wiring Diagram ('02) For E-03, 28, 33
442
Wiring Diagram ('02) For E-24
443
Wiring Diagram ('02) For The Others
444
Wire Harness Routing
445
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1
...
445
446
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Table of Contents
Troubleshooting
FI system troubleshooting
182
Troubleshooting
374
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