GSX-R1000

Suzuki GSX-R1000 User Manual

Suzuki GSX-R1000

641 pages

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Prepared by

March, 2009

Part No. 99500-39380-01E

Printed in Japan

640

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

email: info@motomatrix.co.uk / www.motomatrix.co.uk

Table of Contents

Default Chapter3
- Table of Contents3
- Precautions5
- General Precautions6
- Electrical Parts7
- Precautions for Electrical Circuit Service7
- Connector / Coupler7
- Clamp8
- ECM / Various Sensors8
- Fuse8
- Switch8
- Open Circuit Check9
- Battery9
- Electrical Circuit Inspection Procedure9
- Continuity Check10
- Voltage Check10
- Short Circuit Check (Wire Harness to Ground)11
- Using the Multi-Circuit Testers12
- Using the Testers12
- General Information13
- Symbols14
- General Description14
- Abbreviations14
- Vehicle Side View15
- Brake Fluid16
- Engine Oil (for USA)16
- Fuel and Oil Recommendation16
- Vehicle Identification Number16
- BREAK-IN Procedures17
- Cylinder Identification17
- Engine Coolant Recommendation17
- Wire Color Symbols18
- Country and Area Codes18
- Warning, Caution and Information Labels Location19
- Component Location20
- Electrical Components Location20
- Specifications22
- Special Tools and Equipment24
- Maintenance and Lubrication28
- Recommended Fluids and Lubricants28
- Periodic Maintenance Schedule Chart29
- Scheduled Maintenance29
- Repair Instructions30
- Air Cleaner Element Inspection30
- Lubrication Points30
- Air Cleaner Element Replacement30
- Exhaust Control Valve Inspection31
- Exhaust Pipe Bolt and Muffler Bolt Inspection31
- Valve Clearance Inspection and Adjustment32
- Electrodes Condition36
- Spark Plug Inspection and Cleaning36
- Spark Plug Replacement36
- Fuel Line Inspection37
- Engine Oil Replacement37
- Evaporative Emission Control System Inspection (E-33 Only)37
- Engine Oil and Filter Replacement37
- Oil Filter Replacement38
- Oil Level Inspection38
- Cooling System Inspection39
- PAIR System Inspection39
- Throttle Cable Play Inspection and Adjustment39
- Throttle Valve Synchronization39
- Radiator Hose Inspection40
- Engine Coolant Change40
- Air Bleeding from the Cooling Circuit40
- Clutch Cable Play Inspection and Adjustment41
- Drive Chain Inspection and Adjustment41
- Drive Chain Length Inspection42
- Drive Chain Slack Adjustment42
- Brake Fluid Level Check43
- Brake System Inspection43
- Drive Chain Cleaning and Lubricating43
- Front and Rear Brake Hose Inspection44
- Brake Pads Check44
- Brake Pedal Height Inspection and Adjustment44
- Brake Hose Replacement44
- Inspect Steering System45
- Steering System Inspection45
- Tire Inspection45
- Tire Pressure45
- Chassis Bolt and Nut Inspection46
- Front Fork Inspection46
- Rear Suspension Inspection46
- Tighten Chassis Bolt and Nut46
- Tightening Torque Specifications48
- Compression Pressure Check48
- Recommended Service Material49
- Special Tool49
- Service Data50
- Tightening Torque List58
- Table of Contents63
- Engine63
Precautions68
- Precautions for Engine68
Engine General Information and Diagnosis69
- Injection Timing Description69
- Self-Diagnosis Function71
- User Mode71
- Schematic and Routing Diagram72
- Component Location75
- Diagnostic Information and Procedures76
Specifications206
- Service Data206
Special Tools and Equipment207
- Special Tool207
Emission Control Devices209
- Fuel Injection System Description209
- Precautions209
  - Precautions for Emission Control Devices209
- General Description209
- Schematic and Routing Diagram214
- Repair Instructions216
- Specifications224
  - Service Data224
  - Tightening Torque Specifications224
- Special Tools and Equipment224
- Precautions225
  - Precautions for Engine Electrical Device225
- Component Location225
  - Engine Electrical Components Location225
- Diagnostic Information and Procedures225
  - Engine Symptom Diagnosis225
- Repair Instructions225
- Specifications233
  - Service Data233
  - Tightening Torque Specifications233
- Special Tools and Equipment234
  - Special Tool234
Engine Mechanical235
- Camshaft and Sprocket Assembly Diagram235
- Schematic and Routing Diagram235
  - Throttle Cable Routing Diagram236
  - Engine Mechanical Symptom Diagnosis237
- Diagnostic Information and Procedures237
  - Compression Pressure Check237
  - Engine Components Removable with the Engine in Place238
- Repair Instructions238
- Specifications318
  - Service Data318
  - Tightening Torque Specifications320
- Special Tools and Equipment321
  - Recommended Service Material321
  - Special Tool322
Engine Lubrication System325
- Precautions325
  - Precautions for Engine Oil325
  - Engine Lubrication System Chart Diagram326
- Schematic and Routing Diagram326
- Diagnostic Information and Procedures329
  - Engine Oil Level Inspection330
  - Oil Pan / Oil Pressure Regulator / Oil Strainer Removal and Installation330
- Repair Instructions330
- Specifications338
  - Service Data338
  - Tightening Torque Specifications338
- Special Tools and Equipment339
  - Recommended Service Material339
  - Special Tool339
Engine Cooling System340
- Precautions for Engine Cooling System340
- Engine Coolant Description340
- Anti-Freeze Proportioning Chart340
- General Description340
  - Cooling Circuit Diagram341
- Schematic and Routing Diagram341
- Diagnostic Information and Procedures343
- Repair Instructions343
- Specifications357
  - Service Data357
  - Tightening Torque Specifications358
- Special Tools and Equipment358
  - Recommended Service Material358
  - Special Tool358
Fuel System359
- Precautions359
  - Precautions for Fuel System359
- General Description360
  - Fuel Injection System Description360
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram361
- Schematic and Routing Diagram361
  - Fuel System Diagnosis362
- Diagnostic Information and Procedures362
  - Fuel Pressure Inspection363
- Repair Instructions363
- Specifications372
  - Service Data372
  - Tightening Torque Specifications372
- Special Tools and Equipment373
  - Recommended Service Material373
  - Special Tool373
Ignition System374
- Immobilizer Description (for E-02, 19, 24, 51)374
- General Description374
- Schematic and Routing Diagram376
  - Ignition System Components Location376
  - Ignition System Symptom Diagnosis377
- Diagnostic Information and Procedures377
  - No Spark or Poor Spark378
  - Ignition Coil and Spark Plug Removal and Installation379
- Repair Instructions379
- Specifications386
  - Service Data386
  - Tightening Torque Specifications386
- Special Tools and Equipment387
- Schematic and Routing Diagram388
  - Starting System Diagram388
- Component Location388
  - Starting System Components Location388
- Diagnostic Information and Procedures388
- Repair Instructions390
- Specifications399
  - Service Data399
  - Tightening Torque Specifications399
- Special Tools and Equipment400
- Schematic and Routing Diagram401
- Component Location401
  - Charging System Components Location401
- Diagnostic Information and Procedures401
- Repair Instructions403
- Specifications412
  - Service Data412
  - Tightening Torque Specifications412
- Special Tools and Equipment413
  - Recommended Service Material413
  - Special Tool413
Exhaust System414
- Precautions for Exhaust System414
- Exhaust Control System Description414
- General Description414
  - Exhaust Control System Operation415
- Repair Instructions417
Specifications427
- Service Data427
- Tightening Torque Specifications427
Special Tools and Equipment428
- Recommended Service Material428
- Suspension429
Precautions430
- Precautions for Suspension430
- Suspension General Diagnosis431
- Suspension and Wheel Symptom Diagnosis431
- Diagnostic Information and Procedures431
- Front Suspension432
- Front Fork Components432
- Repair Instructions432
- Front Fork Removal and Installation433
- Front Suspension Adjustment435
- Front Fork Disassembly and Assembly435
  - Spring Pre-Load Adjustment435
  - Damping Force Adjustment435
- Front Fork Parts Inspection441
  - Slide Bushing / Guide Bushing441
  - Fork Spring441
- Rod Guide Case Tightening Torque441
- Specifications442
- Service Data442
- Tightening Torque Specifications442
- Special Tools and Equipment443
- Recommended Service Material443
- Special Tool443
- Rear Suspension Components444
- Repair Instructions444
- Rear Suspension Assembly Construction445
- Rear Shock Absorber Removal and Installation446
- Rear Suspension Inspection446
- Rear Shock Absorber Bearing Removal and Installation447
- Rear Shock Absorber Adjustment448
  - Rebound Side448
  - STD Position448
  - Compression Side (Low Speed)449
  - Compression Side (High Speed)449
  - Gas Pressure Release449
- Rear Shock Absorber Disposal449
- Cushion Lever Removal and Installation450
- Cushion Rod Removal and Installation450
- Cushion Lever Inspection450
  - Collar and Spacer451
  - Cushion Rod Bearing451
- Cushion Rod Inspection451
- Cushion Rod Bearing Removal and Installation452
- Swingarm Removal and Installation452
- Special Tool454
- Swingarm Pivot Boss Removal and Installation455
- Swingarm Related Parts Inspection455
- Swingarm Bearing Removal and Installation456
  - Plate456
  - Swingarm Pivot Shaft456
- Specifications458
- Service Data458
- Tightening Torque Specifications458
- Special Tools and Equipment459
- Recommended Service Material459
- Special Tool459
- Wheels and Tires460
- Precautions for Wheel and Tire460
- Front Wheel Components461
- Repair Instructions461
- Front Wheel Assembly Construction462
- Front Wheel Assembly Removal and Installation463
  - Dust Seal465
  - Wheel Axle465
  - Wheel Axle Runout465
- Front Wheel Related Parts Inspection465
- Front Wheel Dust Seal / Bearing Removal and Installation466
- Rear Wheel Components468
- Rear Wheel Assembly Construction469
- Rear Wheel Assembly Removal and Installation470
- Rear Wheel Related Parts Inspection471
- Rear Wheel Dust Seal / Bearing Removal and Installation472
- Tire Removal and Installation473
- Wheel / Tire / Air Valve Inspection and Cleaning475
- Air Valve Removal and Installation475
- Wheel Balance Check and Adjustment476
- Specifications477
- Service Data477
- Tightening Torque Specifications477
- Special Tools and Equipment478
- Recommended Service Material478
- Special Tool478
- Driveline / Axle479
Precautions480
- Precautions for Driveline / Axle480
- Drive Chain / Drive Train / Drive Shaft481
- Drive Chain and Sprocket Symptom Diagnosis481
- Drive Chain Related Components481
- Diagnostic Information and Procedures481
- Repair Instructions481
- Engine Sprocket Removal and Installation482
- Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation483
- Drive Chain Related Parts Inspection485
- Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation485
  - Engine Sprocket and Rear Sprocket485
  - Wheel Damper485
- Drive Chain Replacement487
- Specifications490
- Service Data490
- Tightening Torque Specifications490
- Special Tools and Equipment491
- Recommended Service Material491
- Special Tool491
- Brake493
Precautions494
- Brake Fluid Information494
- Precautions for Brake System494
- Brake Control System and Diagnosis495
- Front Brake Hose Routing Diagram495
- Schematic and Routing Diagram495
- Rear Brake Hose Routing Diagram496
- Brake Symptom Diagnosis497
- Front Brake Light Switch Inspection497
- Diagnostic Information and Procedures497
- Repair Instructions497
- Brake Pedal Height Inspection and Adjustment497
- Rear Brake Light Switch Inspection and Adjustment498
- Air Bleeding from Brake Fluid Circuit498
- Brake Fluid Level Check498
- Brake Hose Inspection498
- Front Brake499
- Brake Fluid Replacement500
- Rear Brake501
- Front Brake Hose Removal and Installation502
- Front Brake Master Cylinder Components503
- Front Brake Master Cylinder Assembly Removal and Installation504
- Front Brake Master Cylinder / Brake Lever Disassembly and Assembly505
- Piston / Rubber Parts507
- Front Brake Master Cylinder Parts Inspection507
- Rear Brake Master Cylinder Components508
- Rear Brake Master Cylinder Assembly Removal and Installation509
- Rear Brake Master Cylinder Disassembly and Assembly510
- Rear Brake Master Cylinder Parts Inspection511
- Rear Brake Pedal Construction512
- Rear Brake Pedal Removal and Installation512
- Specifications513
- Service Data513
- Tightening Torque Specifications513
- Special Tools and Equipment514
- Recommended Service Material514
- Special Tool514
- Front Brake Components515
- Repair Instructions515
- Front Brake Pad Inspection516
- Front Brake Pad Replacement516
- Front Brake Caliper Removal and Installation517
- Front Brake Caliper Disassembly and Assembly517
  - Brake Caliper Cylinder519
  - Brake Caliper Piston519
  - Brake Pad Mounting Pin519
  - Brake Pad Spring519
- Front Brake Caliper Parts Inspection519
- Front Brake Disc Removal and Installation520
- Front Brake Disc Inspection520
  - Brake Disc Thickness520
  - Brake Disc Runout520
- Specifications521
- Service Data521
- Tightening Torque Specifications521
- Special Tools and Equipment522
- Recommended Service Material522
- Special Tool522
- Rear Brake Components523
- Repair Instructions523
- Rear Brake Pad Inspection524
- Rear Brake Pad Replacement524
- Rear Brake Caliper Removal and Installation525
- Rear Brake Caliper Disassembly and Assembly526
  - Brake Caliper Sliding Pin528
  - Boot528
- Rear Brake Disc Removal and Installation528
- Rear Brake Caliper Parts Inspection528
- Rear Brake Disc Inspection529
- Specifications529
- Service Data529
- Tightening Torque Specifications530
- Special Tools and Equipment530
- Recommended Service Material530
- Special Tool530
- Transmission / Transaxle531
Precautions532
- Precautions for Transmission / Transaxle532
- Manual Transmission Symptom Diagnosis533
- Diagnostic Information and Procedures533
- Transmission Components534
- Repair Instructions534
- Transmission Removal535
  - Countershaft Assembly535
  - Gearshift Fork and Gearshift Cam535
  - Driveshaft Assembly535
  - Bearing and Oil Seal536
- Transmission Installation537
- Transmission Construction541
- Countershaft Gear / Driveshaft Gear Disassembly and Assembly542
  - Driveshaft543
  - Countershaft543
- Transmission Related Parts Inspection544
  - Gearshift Fork to Groove Clearance544
  - Gearshift Fork Groove Width544
  - Gearshift Fork Thickness544
  - Gearshift Cam545
  - Gearshift Cam Bearing545
  - Driveshaft Bearing545
  - Driveshaft Oil Seal545
- Gear Position (GP) Switch Inspection545
- Gear Position (GP) Switch Removal and Installation546
- Gearshift Lever Construction547
- Gearshift Lever Removal and Installation547
- Gearshift Lever Height Inspection and Adjustment548
- Gearshift Shaft / Gearshift Cam Plate Components548
- Gearshift Shaft Construction549
- Gearshift Shaft / Gearshift Cam Plate Removal and Installation549
- Gearshift Shaft Bearing552
- Gearshift Shaft Oil Seal / Bearing Removal and Installation552
- Gearshift Linkage Inspection552
- Specifications553
- Service Data553
- Tightening Torque Specifications554
- Special Tools and Equipment554
- Recommended Service Material554
- Special Tool555
- Clutch System Symptom Diagnosis556
- Precautions556
- Precautions for Clutch System556
- Schematic and Routing Diagram556
- Clutch Cable Routing Diagram556
- Diagnostic Information and Procedures556
- Clutch Lever Position Switch Inspection557
- Clutch Cable Removal and Installation557
- Repair Instructions557
- Clutch Control System Components558
- Clutch Components559
- Clutch Removal560
- Clutch Installation562
  - Clutch Drive and Driven Plate566
  - Clutch Drive Plate Claw Width566
  - Clutch Driven Plate Distortion566
  - Clutch Spring566
- Clutch Parts Inspection566
  - Clutch Release Bearing567
  - Push Rod (Right)567
  - Clutch Sleeve Hub and Primary Driven Gear Assembly567
  - Wave Spring Washer567
- Clutch Lifter Pin Inspection and Adjustment568
- Specifications569
- Service Data569
- Tightening Torque Specifications569
- Special Tools and Equipment570
- Recommended Service Material570
- Special Tool570
- Steering571
Precautions572
- Precautions for Steering572
- Steering General Diagnosis573
- Steering Symptom Diagnosis573
- Diagnostic Information and Procedures573
- Steering / Handlebar574
- Handlebar Components574
- Repair Instructions574
- Handlebar Removal and Installation575
- Handlebars Inspection577
- Steering Components578
- Steering Damper Construction579
- Steering / Steering Damper Removal and Installation579
- Steering Stem Nut581
- Steering / Steering Damper Related Parts Inspection582
  - Steering Stem Upper Bracket582
  - Steering Damper582
- Steering Stem Bearing Removal and Installation583
- Steering System Inspection583
- Steering Tension Adjustment584
  - Outer Race584
  - Inner Race584
- Specifications585
- Tightening Torque Specifications585
- Special Tools and Equipment586
- Recommended Service Material586
- Special Tool586
- Body and Accessories587
Precautions589
- Precautions for Electrical System589
- Component Location589
- Electrical Components Location589
- Wiring Systems590
- Schematic and Routing Diagram590
- Wiring Diagram590
- Wiring Harness Routing Diagram596
- Specifications600
- Service Data600
- Tightening Torque Specifications600
- Special Tools and Equipment600
- Recommended Service Material600
- Lighting Systems601
- Headlight Components601
- Headlight Removal and Installation601
- Repair Instructions601
- Headlight Bulb and Position Light Bulb Replacement602
  - Low Beam Bulb602
  - High Beam Bulb602
- Headlight Beam Adjustment603
- Position Light Bulb603
- Front Turn Signal Light Components603
- Front Turn Signal Light Removal and Installation604
- Front Turn Signal Light Bulb Replacement604
- Rear Lighting System Construction605
- Rear Combination Light Removal and Installation606
- Rear Combination Light Replacement606
- License Plate Light Components607
- License Plate Light Removal and Installation607
- License Plate Light Bulb Replacement608
- Rear Turn Signal Light Components609
- Rear Turn Signal Light Removal and Installation609
- Rear Turn Signal Light Bulb Replacement610
- Reflex Reflector Construction610
- Turn Signal / Side-Stand Relay Inspection611
- Hazard Switch Inspection611
- Turn Signal / Side-Stand Relay Removal and Installation611
- Turn Signal Switch Inspection612
- Dimmer / Passing Light Switch Inspection612
- Specifications613
- Service Data613
- Tightening Torque Specifications613
- Special Tools and Equipment613
- Recommended Service Material613
- Special Tool613
- Combination Meter / Fuel Meter / Horn614
- Combination Meter System Description614
  - LED (Light Emitting Diode)614
  - Engine RPM Indicator Light614
- General Description614
- Combination Meter Components615
- Combination Meter Removal and Installation615
- Repair Instructions615
- Combination Meter Disassembly and Assembly616
- Combination Meter Inspection616
- Stepping Motor Inspection and Adjustment616
- Engine Coolant Temperature Indicator Light Inspection617
- ECT Sensor Removal and Installation617
- Fuel Level Indicator Inspection618
- Fuel Level Gauge Inspection618
- Speedometer Inspection618
- Speed Sensor Removal and Installation618
- Speed Sensor Inspection619
- Oil Pressure Indicator Inspection619
- Oil Pressure Switch Inspection620
- Ignition Switch Inspection620
- Oil Pressure Switch Removal and Installation620
- Ignition Switch Removal and Installation620
- Horn Inspection621
- Horn Removal and Installation621
- Specifications622
- Service Data622
- Tightening Torque Specifications622
- Special Tools and Equipment622
- Exterior Parts Construction623
- Repair Instructions623
- Rear Fender Construction624
- Frame Cover Construction625
- Rear View Mirror Construction626
- Fastener Removal and Installation627
- Exterior Parts Removal and Installation628
  - Side Frame Cover628
  - Rear Seat / Seat Tail Cover628
  - Windscreen629
  - Body Cowling Cover630
  - Side Cowling630
  - Inner under Cowling631
  - Body Cowling631
  - Intake Pipe632
  - Cowling Brace632
  - Frame Cover633
- Specifications634
- Tightening Torque Specifications634
- Body Structure635
- Body Frame Construction635
- Repair Instructions635
- Front Footrest Bracket Construction636
- Side-Stand Construction637
- Pillion Footrest Construction638
- Side-Stand Removal and Installation638
- Specifications639
- Tightening Torque Specifications639
- Special Tools and Equipment639
- Recommended Service Material639

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Suzuki GSX-R1000 Specifications

General

Brand	Suzuki
Model	GSX-R1000
Category	Motorcycle
Language	English

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