Table Of Contents - Suzuki GSX-R1000 Service Manual

Table of Contents

Group Index3
Supplements4
Component Parts And Work To Be Done5
Symbol6
Abbreviations Used In This Manual7
Sae-To-Former Suzuki Term9
Wire Color11
General Information12
Warning/Caution/Note13
General Precautions13
Suzuki Gsx-R1000K5 ('05-Model)15
Serial Number Location15
Fuel, Oil And Engine Coolant Recommendation Fuel (For Usa And Canada)16
Fuel (For Other Countries)16
Engine Oil (For Usa)16
Front Fork Oil17
Engine Coolant17
Water For Mixing17
Anti-Freeze/Engine Coolant17
Braek-In Procedures18
Cylinder Identification18
Information Labels19
Specifications20
Periodic Maintenance22
Periodic Maintenance Schedule23
Periodic Maintenance Chart23
Lubrication Points24
Maintenance And Tune-Up Procedures25
Air Cleaner25
Spark Plug26
Valve Clearance28
Intake Side31
Exhaust Side32
Engine Oil And Oil Filter33
Exhaust Control Valve34
Oil Filter Replacement34
Fuel Line35
Engine Idle Speed35
Throttle Valve Synchronization36
Evaporative Emission Control System (E-33 Only)36
Pair (Air Supply) System36
Throttle Cable Play36
Clutch37
Cooling System38
Engine Coolant Level Check38
Engine Coolant Change38
Air Bleeding The Cooling Circuit39
Radiator Hoses40
Drive Chain41
Cleaning And Lubricating43
Brake44
Brake Fluid Level Check44
Brake Pads45
Brake Pedal Height46
Brake Light Switch46
Air Bleeding From Brake Fluid Circuit46
Front Brake (Caliper Side)47
Front Brake (Master Cylinder Side)47
Rear Brake47
Tires48
Steering48
Tire Tread Condition48
Tire Pressure48
Front Fork49
Rear Suspension49
Exhaust Pipe Bolt And Nut50
Chassis Bolts And Nuts51
Compression Pressure Check53
Compression Test Procedure53
Oil Pressure Check54
Sds Check55
Data Sampled From Cold Starting Through Warm-Up55
Data At 3000 R/Min Under No Load56
Data At The Time Of Racing56
Data Of Intake Negative Pressure During Idling (100 °C)57
Data Of Secondary Throttle Valve Operation At The Time Of Starting57
Engine58
Engine Components Removable With Engine In Place59
Engine Removal And Installation60
Engine Mounting66
Engine Installation67
Engine Disassembly72
Engine Components Inspection And Service84
Cylinder Head Cover84
Cmp Sensor84
Pair Reed Valve84
Camshaft85
Cam Chain Tension Adjuster87
Cam Chain Tensioner88
Cam Chain Guide88
Cylinder Head And Valve88
Clutch Drive Plate Inspection100
Clutch Driven Plate Inspection101
Clutch Spring Inspection101
Clutch Bearing Inspection101
Clutch Lifter102
Clutch Lifter Pin Adjustment102
Oil Pump103
Wave Spring Washer Inspection103
Starter Clutch104
Generator104
Gearshift System105
Gearshift Shaft/Gearshift Arm Disassembly105
Gearshift Shaft/Gearshift Arm Inspection105
Gearshift Shaft/Gearshift Arm Resassembly105
Oil Pressure Regulator106
Oil Strainer106
Transmission107
Transmission Parts Location109
Cylinder110
Cylinder Distortion110
Cylinder Bore110
Piston And Piston Ring111
Piston Diameter111
Piston-To-Cylinder Clearance111
Piston Pin And Pin Bore111
Piston Ring-To-Groove Clearance112
Piston Ring Free End Gap And Piston Ring End Gap112
Crankcase113
Gearshift Fork And Gearshift Cam113
Gearshift Fork-To-Groove Clearance113
Gearshift For Groove Width113
Gearshift Fork Thickness114
Gearshift Cam Bearing And Gearshift Shaft Bearing114
Oil Jet117
Plug118
Balancer Shaft120
Balancer Shaft Journal Bearing120
Crankshaft And Conrod122
Crankshaft Runout122
Conrod Big End Side Clearance123
Conrod-Big End Bearing Inspection123
Conrod-Big End Bearing Selection123
Crank Pin O.d.125
Bearing Thickness125
Crankshaft Journal Bearing126
Bearing Selection Table127
Crankcase I.d. Specification127
Crankshaft Journal O.d. Specification128
Bearing Thickness Specification128
Crankshaft Thrust Bearing129
Crankshaft Thrust Clearance Adjustment129
Thrust Bearing Selection Table130
Engine Reassembly131
Piston And Conrod132
Fi System Diagnosis164
Precautions In Servicing166
Electrical Parts166
Connector/Coupler166
Fuse167
Ecm/Various Sensors167
Electrical Circuit Inspection Procedure169
Open Circuit Check169
Continuity Check170
Short Circuit Check (Wire Harness To Ground)171
Using The Multi-Circuit Tester172
Fi System Technical Features173
Injection Time (Injection Volume)173
Compensation Of Injection Time (Volume)174
Injection Stop Control174
Fi System Parts Location175
Fi System Wiring Diagram177
Ecm Terminal178
Self-Diagnosis Function180
User Mode180
Dealer Mode181
Tps Adjustment183
Fail-Safe Function184
Fi System Troubleshooting186
Customer Complain Analysis186
Visual Inspection187
Self-Diagnosis Procedures188
Self-Diagnosis Reset Procedure188
Use Of Sds Diagnostic Procedures189
Use Of Sds Diagnosis Reset Procedure190
Show Data When Trouble (Displaing Data At The Time Of Dtc)191
Malfunction Code And Defective Condition192
"C11" (P0340) Cmp Sensor Circuit Malfunction196
"C12" (P0335) Ckp Sensor Circuit Malfunction198
"C13" (P0105-H/L) Iap Sensor Circuit Malfunction200
"C14" (P0120-H/L) Tp Sensor Circuit Malfunction206
"C15" (P0115-H/L) Ect Sensor Circuit Malfunction211
"C21" (P0110-H/L) Iat Sensor Circuit Malfunction215
"C22" (P1450-H/L) Ap Sensor Circuit Malfunction219
"C23" (P1651-H/L) To Sensor Circuit Malfunction224
"C28" (P1655) Stv Actuator Circuit Malfunction228
Active Control Inspection230
"C29" (P1654-H/L) Stp Sensor Circuit Malfunction231
"C31" (P0705) Gp Switch Circuit Malfunction236
"C32" (P0201), "C33" (P0202), "C34" (P0203) Or "C35" (P0204) Primary Fuel Injector Circuit Malfunction238
"C36" (P1764), "C37" (P1765), "C38" (P1766) Or "C39" (P1767) Secondary Fuel Injector Circuit Malfunction240
"C41" (P0230-H/L) Fp Relay Circuit Malfunction242
"C42" (P01650) Ig Switch Circuit Malfunction244
"C46" (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction245
"C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction254
"C60" (P0480) Cooling Fan Relay Circuit Malfunction256
Sensors258
Fuel System And Throttle Body262
Fuel Delivery System263
Fuel System264
Fuel Tank Lift-Up264
Fuel Tank Removal264
Fuel Tank Installation265
Fuel Pressure Inspection265
Fuel Pump Inspection266
Fuel Discharge Amount Inspection266
Fuel Pump Relay Inspection267
Fuel Pump And Fuel Filter Removal268
Construction268
Fuel Mesh Filter Inspection And Cleaning270
Fuel Pump And Fuel Mesh Filter Installation270
Throttle Body (Construction)273
Air Cleaner Box Removal274
Throttle Body Removal275
Throttle Body Disassembly276
Throttle Body Cleaning278
Throttle Body Reassembly279
Throttle Body Installation282
Air Cleaner Box Installation283
Fuel Injector Removal284
Fuel Injector Inspection284
Fuel Injector Installation284
Fast Idle285
Fast Idle Adjustment285
Use Of Digital Vacuum Tester287
Use Of Vacuum Balancer Gauge288
Throttle Position Sensor (Tps) Setting290
Exhaust System292
Exhaust Control System293
Operation294
Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)295
Excva Removal295
Excva Installation297
Excv Cable Replacement299
Excva Adjustment301
Excv/Muffler Removal304
Excv Inspection305
Excv/Muffler Installation305
Cooling And Lubrication System308
Cooling Circuit310
Cooling Circuit Inspection310
Radiator And Water Hoses311
Radiator Removal311
Radiator Cap Inspection311
Radiator Inspection And Cleaning311
Radiator Installation312
Water Hose Inspection312
Cooling Fan313
Cooling Fan Relay Inpection314
Ect Sensor314
Thermostat316
Water Pump318
Mechanical Seal320
Oil Seal320
Impeller Shaft Journal320
Seal Washer320
Engine Lubrication System Chart326
Engine Lubrication System327
Chassis330
Exterior Parts332
Fastener Removal And Installation332
Screen334
Body Cowling Cover And Lower Bracket Cover334
Under Cowling334
Body Cowling335
Ait Intake Pipe336
Cowling Brace336
Front Seat336
Rear Seat And Seat Tail Cover337
Frame Cover337
Front Wheel (Construction)338
Axle Shaft340
Wheel340
Wheel Bearings340
Reassembly And Installation342
Front Fork (Construction)346
Inner And Outer Tubes350
Damper Rod350
Oil Seal And Dust Seal351
Damper Rod Bolt351
Fork Oil352
Front Fork Inner Rod Lock Nut353
Fork Spring353
Front Fork Cap Bolt353
Suspension Setting355
Steering Damper (Construction)357
Steering (Construction)359
Front Fork And Steering Stem Upper Bracket363
Steering Tension Adjustment364
Handlebars (Construction)365
Rear Wheel (Construction)369
Wheel Damper375
Dust Seals375
Brake Disc376
Rear Axle376
Rear Shock Absorber (Construction)377
Rear Shock Absorber Disposal379
Gas Pressure Release379
Damping Force Adjustment380
Rear Suspension (Construction)381
Swingarm Pivot Boss Removal And Installation383
Cushion Lever Bearing385
Cushion Lever And Cushion Lever Rods385
Swingarm Pivot Shaft386
Chain Buffer386
Reassembly387
Swingarm Pivot Thrust Clearance Adjustment389
Final Inspection And Adjustment390
Shock Absorber And Cushion Lever Mounting Nut390
Front Brake (Construction)391
Brake Pad Replacement392
Brake Fluid Replacement393
Caliper Removal394
Caliper Disassembly394
Caliper Inspection395
Caliper Reassembly395
Brake Disc Inspection397
Master Cylinder Removal And Disassembly398
Master Cylinder Inspection399
Master Cylinder Reassembly400
Master Cylinder Installation401
Rear Brake (Construction)402
Master Cylinder Removal408
Tire And Wheel411
Tire Removal411
Valve Inspection412
Tire Installation413
Balancer Weight Installation414
Drive Chain Cutting415
Drive Chain Connecting416
Joint Plate Installation416
Joint Pin Staking417
Electrical System420
Cautions In Servicing422
Location Of Electrical Components425
Charging System427
Troubleshooting427
Battery Runs Down Quickly427
Battery Overcharges428
Battery Current Leakage428
Starter System And Side-Stand/Ignition Interlock System431
Starter Motor Will Not Run431
Starter Motor Removal432
Starter Motor Runs But Does Not Crank The Engine432
Starter Motor Disassembly433
Starter Motor Inspection433
Starter Relay Inspection435
Side Stand/Ignition Interlock System Parts Inspection436
Turn Signal/Side-Stand Relay438
Side-Stand Relay Inspection438
Diode Inspection438
Ignition System439
Immobilizer (Except For E-03, 28, 33)440
No Spark Or Poor Spark442
Ignition Coil Primary Peak Voltage444
Combination Meter448
Fuel Level Indicator Light Inspection452
Lamps454
Headlight, Brake Light/Taillight, License Plate Light And Turn Signal Light454
Relays456
Ignition Switch Removal457
Ignition Switch Installation457
Switches Inspection458
Battery Specifications459
Initial Charging459
Servicing461
Recharging Operation461
Servicing Information462
Fi System Malfunction Code And Defective Condition464
Radiator (Cooling System)474
Brakes476
Electrical477
Battery478
Wiring Harness, Cable And Hose Routing479
Wiring Harness Routing479
Cable Routing482
Throttle Body Hose Routing483
Fuel Tank Drain Hose Routing484
Cooling System Hose Routing485
Front Brake Hose Routing486
Rear Brake Hose Routing487
Pair (Air Supply) System Hose Routing488
Fuel Tank Lower Side Cover Cushion Rubber/Fastener Installation490
Cowling Installation491
Frame Cover Installation492
Seat Lock Cable Routing492
Rear Fender Installation493
Under Cowling Heat Shield Installation494
Body Cowling Cover Cushion Installation495
Windscreen Tape Cushion Installation495
Headlight Tape Cushion Installation496
Air Intake Cover Tape Cushion Installation496
Side-Stand Installation497
Gearshift Pedal Installation497
Handlebar Balancer498
Front Footrest Installation498
Rear View Mirror Installation499
Rear Combinator Light Installation500
Regulator/Rectifier Installation501
Special Tools502
Tightening Torque506
Tightening Torque Chart509
Service Data510
Valve + Valve Guide510
Camshaft + Cylinder Head510
Cylinder + Piston + Piston Ring511
Conrod + Crankshaft512
Balancer512
Transmission + Drive Chain513
Thermostat + Radiator + Fan + Coolant514
Injector + Fuel Pump + Fuel Pressure Regulator514
Fi Sensors515
Throttle Body516
Wattage517
Brake + Wheel517
Tire518
Suspension519
Fuel + Oil519
Emission Control Information520
Emission Control Systems521
Fuel Injection System521
Crankcase Emission Control System522
Exhaust Emission Control System (Pair System)523
Noise Emission Control System524
Evaporative Emission Control System (Only For E-33)524
Pair (Air Supply) System And Emission Control System Inspection525
Pair (Air Supply) System Diagram527
Fuel-Shut Off Valve530
Evap Canister Hose Routing (Only For E-33)531
Gsx-R1000K6532
Battery Holder Cushion Rubber Installation544
Wiring Diagram E-02, 19, 24545
E-03, 28, 33546