Suzuki GSX-R1000K5 Manuals

Suzuki GSX-R1000K5 Manuals

Manuals and User Guides for Suzuki GSX-R1000K5. We have 1 Suzuki GSX-R1000K5 manual available for free PDF download: Service Manual

Suzuki GSX-R1000K5 Service Manual

Suzuki GSX-R1000K5 Service Manual (525 pages)

Brand: Suzuki | Category: Motorcycle | Size: 29.47 MB

Table of Contents

Foreword Group Index

3
General Information 1

9
- General Precautions
  10
- Warning/Caution/Note
  10
- Serial Number Location
  12
- Suzuki Gsx-R1000K5 ('05-Model)
  12
- Fuel, Oil and Engine Coolant Recommendation
  13
  - Fuel (for Usa and Canada)
    13
  - Fuel (for Other Countries)
    13
  - Engine Oil (for Usa)
    13
  - Engine Oil (for Other Countries)
    13
  - Brake Fluid
    13
  - Front Fork Oil
    14
  - Engine Coolant
    14
  - Water for Mixing
    14
  - Anti-Freeze/Engine Coolant
    14
  - Liquid Amount of Water/Engine Coolant
    14
- Break-In Procedures
  15
- Cylinder Identification
  15
- Information Labels
  16
- Specifications
  17
  - Dimensions and Dry Mass
    17
  - Engine
    17
  - Drive Train
    17
  - Chassis
    18
  - Electrical
    18
  - Capacities
    18
Periodic Maintenance

19
- Periodic Maintenance Schedule
  20
  - Periodic Maintenance Chart
    20
  - Lubrication Points
    21
- Maintenance and Tune-Up Procedures
  22
  - Air Cleaner
    22
  - Spark Plug
    23
  - Valve Clearance
    25
  - Engine Oil and Oil Filter
    30
  - Exhaust Control Valve
    31
  - Fuel Line
    32
  - Engine Idle Speed
    32
  - Throttle Valve Synchronization
    33
  - Evaporative Emission Control System (E-33 Only)
    33
  - Pair (Air Supply) System
    33
  - Throttle Cable Play
    33
  - Clutch
    34
  - Cooling System
    35
    
    ENGINE COOLANT Change
    35
    
    Engine Coolant Level Check
    35
  - Drive Chain
    38
  - Brake
    41
  - Tires
    45
  - Steering
    45
  - Tire Tread Depth
    45
  - Front Fork
    46
  - Rear Suspension
    46
  - Exhaust Pipe Bolt and Nut
    47
  - Chassis Bolts and Nuts
    48
- Compression Pressure Check
  50
  - Compression Test Procedure
    50
- Oil Pressure Check
  51
- Sds Check
  52
- Data at the Time of Racing
  53
Engine

55
- Engine Components Removable with Engine in Place
  56
- Engine Removal and Installation
  57
  - Engine Removal
    57
  - Engine Installation
    64
- Engine Disassembly
  69
- Engine Components Inspection and Service
  81
  - Cylinder Head Cover
    81
  - Cmp Sensor
    81
  - Pair Reed Valve
    81
  - Camshaft
    82
  - Camshaft Runout
    84
  - Cam Chain Tension Adjuster
    84
  - Cam Chain Tensioner
    85
  - Cam Chain Guide
    85
  - Cylinder Head and Valve
    85
  - Clutch
    97
  - Clutch Lifter
    99
  - Oil Pump
    100
  - Starter Clutch
    101
  - Generator
    101
  - Water Pump
    102
  - Gearshift System
    102
  - Oil Pressure Regulator
    103
  - Oil Strainer
    103
  - Transmission
    104
  - Cylinder
    107
  - Piston and Piston Ring
    108
    
    Piston Diameter
    108
    
    Piston Ring Groove Width
    109
    
    Piston Ring Thickness
    109
    
    Piston Ring End Gap
    109
  - Crankcase
    110
  - Balancer Shaft
    117
  - Balancer Shaft Journal Bearing
    117
  - Crankshaft and Conrod
    119
  - Crankshaft Runout
    119
  - Crankshaft Journal Bearing
    123
  - Crankshaft Thrust Bearing
    126
- Engine Reassembly
  128
Fi System Diagnosis

161
Fuel System and Throttle Body

258
- Fuel System and Throttle
  258
  - Fuel Delivery System
    259
  - Fuel System
    260
    
    Fuel Tank Lift-Up
    260
    
    Fuel Tank Removal
    260
    
    Fuel Tank Installation
    261
    
    Fuel Pressure Inspection
    261
    
    Fuel Pump Inspection
    262
    
    Fuel Discharge Amount Inspection
    262
    
    Fuel Pump Relay Inspection
    263
    
    Fuel Pump and Fuel Filter Removal
    264
    
    Fuel Mesh Filter Inspection and Cleaning
    266
    
    Fuel Pump and Fuel Mesh Filter Installation
    266
  - Throttle Body
    269
    
    Construction
    269
    
    Air Cleaner Box Removal
    270
    
    Throttle Body Removal
    271
    
    Throttle Body Disassembly
    272
    
    Throttle Body Cleaning
    274
    
    Inspection
    274
    
    Throttle Body Reassembly
    275
    
    Throttle Body Installation
    278
    
    Air Cleaner Box Installation
    279
    
    Stp Sensor Adjustment
    279
    
    Fuel Injector Removal
    280
    
    Fuel Injector Inspection
    280
    
    Fuel Injector Installation
    280
    
    Fast Idle
    281
    
    Fast Idle Adjustment
    281
    
    Throttle Valve Synchronization
    283
    
    Throttle Position Sensor (Tps) Setting
    286
Exhaust System

287
- Exhaust System
  288
  - Exhaust Control System
    288
  - Operation
    289
- Excva (Exhaust Control Valve Actuator) and Excv (Exhaust Control Valve)
  290
  - Excva Removal
    290
  - Excva Installation
    292
  - Excva Inspection
    294
  - Excv Cable Replacement
    294
  - Excva Adjustment
    296
  - Excv/Muffler Removal
    299
  - Excv Inspection
    300
  - Excv/Muffler Installation
    300
  - Exhaust Pipe Removal
    301
  - Exhaust Pipe Installation
    301
Cooling and Lubrication System

303
- Engine Coolant
  304
- Cooling Circuit
  305
  - Cooling Circuit Inspection
    305
- Radiator and Water Hoses
  306
  - Radiator Removal
    306
  - Radiator Cap Inspection
    306
  - Radiator Inspection and Cleaning
    306
  - Radiator Installation
    307
  - Water Hose Inspection
    307
- Cooling Fan
  308
  - Removal
    308
  - Inspection
    308
  - Installation
    308
  - Cooling Fan Relay Inspection
    309
- Ect Sensor
  309
  - Removal
    309
  - Inspection
    309
  - Installation
    310
- Thermostat
  311
  - Removal
    311
  - Inspection
    311
  - Installation
    312
- Water Pump
  313
  - Removal and Disassembly
    313
  - Inspection
    315
  - Reassembly and Installation
    316
- Lubrication System
  319
  - Oil Pressure
    319
  - Oil Filter
    319
  - Oil Pressure Regulator
    319
  - Oil Strainer
    319
  - Oil Jet
    319
  - Oil Pump
    319
  - Oil Pressure Switch
    319
  - Oil Cooler
    319
  - Engine Lubrication System Chart
    321
  - Oil Pan
    321
  - Engine Lubrication System
    322
Chassis

324
- Exterior Parts
  326
  - Fastener Removal and Installation
    326
  - Screen
    328
  - Body Cowling Cover and Lower Bracket Cover
    328
  - Under Cowling
    328
  - Body Cowling
    329
  - Air Intake Pipe
    330
  - Cowling Brace
    330
  - Front Seat
    330
  - Fuel Tank Lower Side Cover
    330
  - Rear Seat and Seat Tail Cover
    331
  - Frame Cover
    331
- Front Wheel
  332
  - Construction
    332
  - Removal
    333
  - Inspection and Disassembly
    334
  - Reassembly and Installation
    336
- Front Fork
  340
  - Construction
    340
  - Removal and Disassembly
    341
  - Inspection
    344
  - Reassembly
    345
  - Installation
    349
  - Suspension Setting
    349
- Steering Damper
  351
  - Construction
    351
  - Removal
    352
  - Inspection
    352
  - Installation
    352
- Steering
  353
  - Construction
    353
  - Removal
    354
  - Inspection and Disassembly
    355
  - Reassembly
    356
  - Installation
    356
  - Steering Tension Adjustment
    358
- Handlebars
  359
  - Construction
    359
  - Removal
    359
  - Installation
    360
- Rear Wheel
  363
  - Construction
    363
  - Removal
    364
  - Inspection and Disassembly
    365
  - Reassembly and Installation
    367
- Rear Shock Absorber
  371
  - Construction
    371
  - Removal
    372
  - Inspection
    372
  - Rear Shock Absorber Disposal
    373
  - Installation
    374
  - Suspension Setting
    374
- Rear Suspension
  375
  - Construction
    375
  - Removal
    376
  - Inspection and Disassembly
    378
  - Reassembly
    381
  - Installation
    383
  - Final Inspection and Adjustment
    384
- Front Brake
  385
  - Construction
    385
  - Brake Pad Replacement
    386
  - Brake Fluid Replacement
    387
  - Caliper Removal
    388
  - Caliper Disassembly
    388
  - Caliper Inspection
    389
  - Caliper Reassembly
    389
  - Caliper Installation
    390
  - Brake Disc Inspection
    391
  - Master Cylinder Removal and Disassembly
    392
  - Master Cylinder Inspection
    393
  - Master Cylinder Reassembly
    394
  - Master Cylinder Installation
    395
- Rear Brake
  396
  - Construction
    396
  - Brake Pad Replacement
    397
  - Brake Fluid Replacement
    398
  - Caliper Removal
    398
  - Caliper Disassembly
    399
  - Caliper Inspection
    399
  - Service Limit
    399
  - Caliper Reassembly
    400
  - Caliper Installation
    401
  - Master Cylinder Removal
    402
  - Master Cylinder Disassembly
    402
  - Master Cylinder Inspection
    403
  - Master Cylinder Reassembly
    403
  - Master Cylinder Installation
    404
- Tire and Wheel
  405
  - Tire Removal
    405
  - Inspection
    405
  - Valve Inspection
    406
  - Tire Installation
    407
  - Balancer Weight Installation
    408
- Drive Chain
  409
  - Drive Chain Cutting
    409
  - Drive Chain Connecting
    410
Electrical System

413
- Cautions in Servicing
  415
  - Connector
    415
  - Coupler
    415
  - Clamp
    415
  - Fuse
    415
  - Semi-Conductor Equipped Part
    416
  - Battery
    416
  - Connecting the Battery
    416
  - Wiring Procedure
    416
  - Using the Multi-Circuit Tester
    417
- Location of Electrical Components
  418
- Charging System
  420
  - Troubleshooting
    420
  - Inspection
    421
- Starter System and Side-Stand/Ignition Interlock System
  424
  - Troubleshooting
    424
  - Starter Motor Removal
    425
  - Starter Motor Disassembly
    426
  - Starter Motor Inspection
    426
  - Starter Motor Reassembly
    427
  - Starter Relay Inspection
    428
  - Side Stand/Ignition Interlock System Parts Inspection
    429
- Ignition System
  432
  - IMMOBILIZER (Except for E-03, 28, 33)
    433
  - Troubleshooting
    435
  - Inspection
    437
- Combination Meter
  441
  - Description
    441
  - Removal and Disassembly
    442
  - Inspection
    443
- Lamps
  447
  - Headlight, Brake Light/Taillight, License Plate Light and Turn Signal Light
    447
- Relays
  449
  - Turn Signal/Side-Stand Relay
    449
  - Starter Relay
    449
  - Fuel Pump Relay
    449
  - Cooling Fan Relay
    449
  - Ignition Switch Removal
    450
  - Ignition Switch Installation
    450
  - Switches Inspection
    451
- Battery
  452
  - Specifications
    452
  - Initial Charging
    452
  - Servicing
    454
  - Recharging Operation
    454
Servicing Information

455
- Troubleshooting
  457
  - Fi System Malfunction Code and Defective Condition
    457
  - Engine
    461
  - Radiator (Cooling System)
    467
  - Chassis
    468
  - Brakes
    469
  - Electrical
    470
  - Battery
    471
- Wiring Harness, Cable and Hose Routing
  472
  - Wiring Harness Routing
    472
  - Cable Routing
    475
  - Throttle Body Hose Routing
    476
  - Fuel Tank Drain Hose Routing
    477
  - Cooling System Hose Routing
    478
  - Front Brake Hose Routing
    479
  - Rear Brake Hose Routing
    480
  - Pair (Air Supply) System Hose Routing
    481
  - Fuel Tank Installation
    482
  - Fuel Tank Lower Side Cover Cushion Rubber
    483
  - Fastener Installation
    483
  - Cowling Installation
    484
  - Frame Cover Installation
    485
  - Seat Lock Cable Routing
    485
  - Rear Fender Installation
    486
  - Under Cowling Heat Shield Installation
    487
  - Body Cowling Cover Cushion Installation
    488
  - Windscreen Tape Cushion Installation
    488
  - Headlight Tape Cushion Installation
    489
  - Air Intake Cover Tape Cushion Installation
    489
  - Side-Stand Installation
    490
  - Gearshift Pedal Installation
    490
  - Handlebar Balancer
    491
  - Front Footrest Installation
    491
  - Rear View Mirror Installation
    492
  - Rear Combination Light Installation
    493
  - Regulator/Rectifier Installation
    494
  - Special Tools
    495
- Tightening Torque
  499
  - Engine
    499
  - Fi System and Intake Air System
    500
  - Cooling System
    500
  - Chassis
    501
  - Tightening Torque Chart
    502
- Service Data
  503
Emission Control Information

513
- Emission Control Systems
  514
- Inspection
  518
  - Pair Hoses
    518
  - Pair Reed Valve
    518
  - Pcv Hose
    518
  - Pair Control Solenoid Valve
    518
- Pair (Air Supply) System and Emission Control System
  518
- Pair (Air Supply) System Diagram
  520
- Pair (Air Supply) System Hose Routing
  521
- Wiring Diagram
  522

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