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Suzuki GSX-R1000 Manuals
Manuals and User Guides for Suzuki GSX-R1000. We have
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Suzuki GSX-R1000 manuals available for free PDF download: Service Manual
Suzuki GSX-R1000 Service Manual (642 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 28.39 MB
Table of Contents
Table of Contents
3
Precautions
5
General Precautions
6
Electrical Parts
7
Precautions for Electrical Circuit Service
7
Connector / Coupler
7
Clamp
8
ECM / Various Sensors
8
Fuse
8
Switch
8
Open Circuit Check
9
Battery
9
Electrical Circuit Inspection Procedure
9
Continuity Check
10
Voltage Check
10
Short Circuit Check (Wire Harness to Ground)
11
Using the Multi-Circuit Testers
12
Using the Testers
12
General Information
13
Symbols
14
General Description
14
Abbreviations
14
Vehicle Side View
15
Brake Fluid
16
Engine Oil (for USA)
16
Fuel and Oil Recommendation
16
Vehicle Identification Number
16
BREAK-IN Procedures
17
Cylinder Identification
17
Engine Coolant Recommendation
17
Wire Color Symbols
18
Country and Area Codes
18
Warning, Caution and Information Labels Location
19
Component Location
20
Electrical Components Location
20
Specifications
22
Special Tools and Equipment
24
Maintenance and Lubrication
28
Recommended Fluids and Lubricants
28
Periodic Maintenance Schedule Chart
29
Scheduled Maintenance
29
Repair Instructions
30
Air Cleaner Element Inspection
30
Lubrication Points
30
Air Cleaner Element Replacement
30
Exhaust Control Valve Inspection
31
Exhaust Pipe Bolt and Muffler Bolt Inspection
31
Valve Clearance Inspection and Adjustment
32
Electrodes Condition
36
Spark Plug Inspection and Cleaning
36
Spark Plug Replacement
36
Fuel Line Inspection
37
Engine Oil Replacement
37
Evaporative Emission Control System Inspection (E-33 Only)
37
Engine Oil and Filter Replacement
37
Oil Filter Replacement
38
Oil Level Inspection
38
Cooling System Inspection
39
PAIR System Inspection
39
Throttle Cable Play Inspection and Adjustment
39
Throttle Valve Synchronization
39
Radiator Hose Inspection
40
Engine Coolant Change
40
Air Bleeding from the Cooling Circuit
40
Clutch Cable Play Inspection and Adjustment
41
Drive Chain Inspection and Adjustment
41
Drive Chain Length Inspection
42
Drive Chain Slack Adjustment
42
Brake Fluid Level Check
43
Brake System Inspection
43
Drive Chain Cleaning and Lubricating
43
Front and Rear Brake Hose Inspection
44
Brake Pads Check
44
Brake Pedal Height Inspection and Adjustment
44
Brake Hose Replacement
44
Inspect Steering System
45
Steering System Inspection
45
Tire Inspection
45
Tire Pressure
45
Chassis Bolt and Nut Inspection
46
Front Fork Inspection
46
Rear Suspension Inspection
46
Tighten Chassis Bolt and Nut
46
Tightening Torque Specifications
48
Compression Pressure Check
48
Recommended Service Material
49
Special Tool
49
Service Data
50
Tightening Torque List
58
Table of Contents
63
Engine
63
Precautions
68
Precautions for Engine
68
Engine General Information and Diagnosis
69
Injection Timing Description
69
Injection Time (Injection Volume)
69
Compensation of Injection Time (Volume)
70
Injection Stop Control
70
Self-Diagnosis Function
71
User Mode
71
Schematic and Routing Diagram
72
Dealer Mode
72
FI System Wiring Diagram
72
Terminal Alignment of ECM Coupler
74
FI System Parts Location
75
Component Location
75
Diagnostic Information and Procedures
76
Engine Symptom Diagnosis
76
Self-Diagnostic Procedures
80
Use of Mode Select Switch
80
Use of SDS
81
Use of SDS Diagnosis Reset Procedures
82
Show Data When Trouble (Displaying Data at the Time of DTC)
83
SDS Check
84
Data at the Time of Racing
86
Data of Intake Negative Pressure During Idling (100 °C)
86
Data of Manifold Absolute Pressure Operation at the Time of Starting
87
Example of Trouble
88
DTC Table
88
Fail-Safe Function Table
90
FI System Troubleshooting
91
Customer Complaint Analysis
91
Visual Inspection
92
Malfunction Code and Defective Condition Table
93
DTC "C11" (P0340): CMP Sensor Circuit Malfunction
97
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
100
DTC "C13" (P0105-H/L): IAP Sensor Circuit Malfunction
103
C13 (Use of Mode Select Switch)
104
P0105-H for IAP Sensor (Use of SDS)
105
P0105-L for IAP Sensor (Use of SDS)
107
DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction
111
C14 (Use of Mode Select Switch)
112
P0120-H (Use of SDS)
113
P0120-L (Use of SDS)
115
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
118
C15 (Use of Mode Select Switch)
119
P0115-H (Use of SDS)
120
P0115-L (Use of SDS)
121
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
123
C21 (Use of Mode Select Switch)
124
P0110-H (Use of SDS)
125
P0110-L (Use of SDS)
126
DTC "C22" (P1450-H/L): AP Sensor Circuit Malfunction
128
C22 (Use of Mode Select Switch)
129
P1450-H (Use of SDS)
130
P1450-L (Use of SDS)
132
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
136
C23 (Use of Mode Select Switch)
137
P1651-H (Use of SDS)
138
P1651-L (Use of SDS)
140
DTC "C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354): Ignition System Malfunction
143
DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
143
Active Control Inspection
146
DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction
147
C29 (Use of Mode Select Switch)
148
P1654-H (Use of SDS)
149
P1654-L (Use of SDS)
151
DTC "C31" (P0705): GP Switch Circuit Malfunction
154
DTC "C32" (P0201), "C33" (P0202), "C34" (P0203) or "C35" (P0204): Primary Fuel Injector Circuit Malfunction
156
DTC "C36" (P1764), "C37" (P1765), "C38" (P1766) or "C39" (P1767): Secondary Fuel Injector Circuit Malfunction
159
DTC "C40" (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction
162
DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction
166
C41 (Use of Mode Select Switch)
167
P0230-H (Use of SDS)
168
P0230-L (Use of SDS)
168
DTC "C41" (P2505): ECM Power Input Signal Malfunction
169
DTC "C42" (P1650): IG Switch Circuit Malfunction
171
DTC "C44" (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction
171
DTC "C46" (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction
177
P1657-L (Use of SDS)
181
DTC "C49" (P1656): PAIR Control Solenoid Valve Circuit Malfunction
189
DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction
192
DTC "C62" (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (E-33 Only)
195
DTC "C91" (P0500): Vehicle Speed Sensor Circuit Malfunction
199
DTC "C93" (P1769): Steering Damper Solenoid Valve Circuit Malfunction
202
Specifications
206
Service Data
206
Special Tools and Equipment
207
Special Tool
207
Emission Control Devices
209
Fuel Injection System Description
209
Precautions
209
Precautions for Emission Control Devices
209
General Description
209
Crankcase Emission Control System Description
210
Exhaust Emission Control System Description
211
PAIR System Diagram
212
Noise Emission Control System Description
212
Evaporative Emission Control System Diagram (Only for E-33)
213
PAIR System Hose Routing Diagram
214
Schematic and Routing Diagram
214
EVAP Canister Hose Routing Diagram (Only for E-33)
215
Heated Oxygen Sensor (HO2S) Removal and Installation
216
PAIR Reed Valve Removal and Installation
216
Repair Instructions
216
PAIR Control Solenoid Valve Removal and Installation
217
PAIR System Inspection
217
PAIR Control Solenoid Valve
218
PAIR Reed Valve
218
Crankcase Breather (PCV) Hose Inspection
219
Crankcase Breather (PCV) Hose / Reed Valve / Cover Removal and Installation
219
Crankcase Breather (PCV) Cover Inspection
220
EVAP System Purge Control Solenoid Valve Removal
220
Evaporative Emission Control System Removal and Installation (Only for E-33)
220
Fuel Shut-Off Valve
221
EVAP Canister
222
EVAP System Purge Control Solenoid Valve
222
Evaporative Emission Control System Inspection (Only for E-33)
222
Specifications
224
Service Data
224
Tightening Torque Specifications
224
Special Tools and Equipment
224
Recommended Service Material
224
Special Tool
224
ECM Removal and Installation
225
Precautions
225
Precautions for Engine Electrical Device
225
Component Location
225
Engine Electrical Components Location
225
Diagnostic Information and Procedures
225
Engine Symptom Diagnosis
225
Repair Instructions
225
CMP Sensor Inspection
226
CMP Sensor Removal and Installation
226
CKP Sensor Inspection
226
CKP Sensor Removal and Installation
226
TP Sensor Removal and Installation
227
TP Sensor Adjustment
227
ECT Sensor Removal and Installation
228
ECT Sensor Inspection
228
IAT Sensor Removal and Installation
229
IAT Sensor Inspection
229
TO Sensor Inspection
229
AP Sensor Inspection
229
TO Sensor Removal and Installation
230
STP Sensor Inspection
230
STP Sensor Adjustment
230
STV Actuator Inspection
231
STV Actuator Removal and Installation
231
ISC Valve Removal and Installation
231
ISC Valve Preset and Opening Initialization
232
HO2 Sensor Inspection
232
HO2 Sensor Removal and Installation
232
GP Switch Inspection
232
Specifications
233
Service Data
233
Tightening Torque Specifications
233
Special Tools and Equipment
234
Special Tool
234
Engine Mechanical
235
Camshaft and Sprocket Assembly Diagram
235
Schematic and Routing Diagram
235
Throttle Cable Routing Diagram
236
Engine Mechanical Symptom Diagnosis
237
Diagnostic Information and Procedures
237
Compression Pressure Check
237
Engine Components Removable with the Engine in Place
238
Repair Instructions
238
Air Cleaner Element Removal and Installation
240
Air Cleaner Box Removal and Installation
241
Air Cleaner Element Inspection and Cleaning
241
Throttle Cable Removal and Installation
241
Throttle Cable Inspection
241
Throttle Cable Play Inspection and Adjustment
241
Throttle Body Components
242
Throttle Body Construction
243
Throttle Body Removal and Installation
244
Throttle Body Disassembly and Assembly
245
Throttle Body Inspection and Cleaning
250
ISC Valve Visual Inspection
250
Throttle Valve Synchronization
250
ISC Valve Reset
252
TP Reset
253
Engine Assembly Removal
254
Engine Assembly Installation
258
Engine Top Side Disassembly
260
Camshafts
261
Engine Top Side Assembly
262
Cylinder Head
262
Cam Chain Tension Adjuster
266
Cylinder Head Cover
268
Cylinder Head Cover Disassembly and Assembly
269
Cylinder Head Cover Related Parts Inspection
270
Camshaft Inspection
270
Cam Wear
270
Camshaft Journal Wear
271
Camshaft Runout
271
Camshaft Sprocket
272
Cam Chain Tension Adjuster Inspection
272
Cam Chain Guide / Cam Chain Tensioner Removal and Installation
273
Cam Chain Guide Inspection
274
Cam Chain Tensioner Inspection
274
Cylinder Head Disassembly and Assembly
274
Cylinder Head Related Parts Inspection
278
Valve Head Radial Runout
279
Valve Stem and Valve Face Wear Condition
279
Valve Stem Deflection
279
Valve Stem Runout
279
Valve Seat Width
280
Valve Spring
280
Valve Stem Wear
280
Valve Guide Replacement
281
Valve Seat Sealing Condition
281
Valve Seat Repair
283
Engine Bottom Side Disassembly
283
Crankcase Breather (PCV) Cover
283
Starter Motor
283
Gearshift System
284
Generator
284
Starter Torque Limiter / Starter Clutch
284
Water Pump
284
Gear Position Switch
285
Oil Filter
285
Oil Pan
285
Oil Pressure Switch
285
Crankcase
286
Oil Pump
286
Balancer Shaft
287
Crankshaft
287
Transmission
287
Piston / Conrod
288
Piston Cooling Oil Jet
288
Crankshaft Journal Bearing
289
Oil Gallery Plug
289
Oil Jet
289
Oil Seal / Bearing
290
Water Jacket Plug
290
Engine Bottom Side Assembly
290
Breather Oil Return Plate
290
Oil Strainer / Oil Pressure Regulator
299
Cylinder Inspection
303
Cylinder Distortion
303
Piston Ring Removal and Installation
303
Piston-To-Cylinder Clearance
303
Piston and Piston Ring Inspection
305
Piston Diameter
305
Piston Ring-To-Groove Clearance
305
Piston Pin and Pin Bore
306
Piston Ring End Gap
306
Piston Ring Free End Gap and Piston Ring End Gap
306
Balancer Shaft Disassembly and Assembly
307
Balancer Shaft Inspection
307
Balancer Shaft Journal Bearing Removal and Installation
308
Balancer Shaft Journal Bearing Inspection and Selection
309
Conrod Crank Pin Bearing Removal and Installation
310
Conrod and Crankshaft Inspection
311
Conrod Big End Side Clearance
311
Conrod Small End I.D.
311
Crankshaft Runout
311
Conrod Crank Pin Bearing Inspection and Selection
312
Crankshaft Journal Bearing Inspection and Selection
313
Bearing Thickness Specification
313
Crank Pin O.D. Specification
313
Crankcase Journal I.D. Specification
314
Crankshaft Journal O.D. Specification
315
Crankshaft Thrust Clearance Inspection and Selection
316
Specifications
318
Service Data
318
Tightening Torque Specifications
320
Special Tools and Equipment
321
Recommended Service Material
321
Special Tool
322
Engine Lubrication System
325
Precautions
325
Precautions for Engine Oil
325
Engine Lubrication System Chart Diagram
326
Schematic and Routing Diagram
326
Oil Pan
326
Engine Lubrication Circuit Diagram
327
Engine Lubrication Symptom Diagnosis
329
Oil Pressure Check
329
Diagnostic Information and Procedures
329
Engine Oil Level Inspection
330
Oil Pan / Oil Pressure Regulator / Oil Strainer Removal and Installation
330
Repair Instructions
330
Engine Oil and Filter Replacement
330
Oil Pressure Regulator / Oil Strainer Inspection
331
Oil Strainer
331
Oil Cooler / Oil Cooler Hose Inspection and Cleaning
331
Oil Cooler / Oil Cooler Hose Removal and Installation
332
Oil Cooler Cleaning
332
Oil Cooler Inspection
332
Oil Pressure Switch Removal and Installation
333
Oil Jet Removal and Installation
334
Oil Pressure Switch Inspection
334
Oil Jet (for Cam Chain Tension Adjuster) Removal
335
Oil Jet (for Transmission) Removal
336
Oil Pump Removal and Installation
336
Oil Jet Inspection
336
Oil Pump Inspection
338
Oil Pump Drive Sprocket Removal and Installation
338
Specifications
338
Service Data
338
Tightening Torque Specifications
338
Special Tools and Equipment
339
Recommended Service Material
339
Special Tool
339
Advertisement
Suzuki GSX-R1000 Service Manual (549 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 17.86 MB
Table of Contents
Group Index
3
Supplements
4
Component Parts and Work to be Done
5
Symbol
6
Abbreviations Used in this Manual
7
SAE-To-Former SUZUKI Term
9
Wire Color
11
General Information
12
Warning/Caution/Note
13
General Precautions
13
SUZUKI GSX-R1000K5 ('05-Model)
15
Serial Number Location
15
Fuel, Oil and Engine Coolant Recommendation Fuel (for USA and Canada)
16
Fuel (for Other Countries)
16
Engine Oil (for USA)
16
Front Fork Oil
17
Engine Coolant
17
Water for Mixing
17
Anti-Freeze/Engine Coolant
17
Braek-In Procedures
18
Cylinder Identification
18
Information Labels
19
Specifications
20
Periodic Maintenance
22
Periodic Maintenance Schedule
23
Periodic Maintenance Chart
23
Lubrication Points
24
Maintenance and Tune-Up Procedures
25
Air Cleaner
25
Spark Plug
26
Valve Clearance
28
Intake Side
31
Exhaust Side
32
Engine Oil and Oil Filter
33
Exhaust Control Valve
34
Oil Filter Replacement
34
Fuel Line
35
Engine Idle Speed
35
Throttle Valve Synchronization
36
Evaporative Emission Control System (E-33 Only)
36
Pair (Air Supply) System
36
Throttle Cable Play
36
Clutch
37
Cooling System
38
Engine Coolant Level Check
38
Engine Coolant Change
38
Air Bleeding the Cooling Circuit
39
Radiator Hoses
40
Drive Chain
41
Cleaning and Lubricating
43
Brake
44
Brake Fluid Level Check
44
Brake Pads
45
Brake Pedal Height
46
Brake Light Switch
46
Air Bleeding from Brake Fluid Circuit
46
Front Brake (Caliper Side)
47
Front Brake (Master Cylinder Side)
47
Rear Brake
47
Tires
48
Steering
48
Tire Tread Condition
48
Tire Pressure
48
Front Fork
49
Rear Suspension
49
Exhaust Pipe Bolt and Nut
50
Chassis Bolts and Nuts
51
Compression Pressure Check
53
Compression Test Procedure
53
Oil Pressure Check
54
SDS Check
55
Data Sampled from Cold Starting through Warm-Up
55
Data at 3000 R/Min under no Load
56
Data at the Time of Racing
56
Data of Intake Negative Pressure During Idling (100 °C)
57
Data of Secondary Throttle Valve Operation at the Time of Starting
57
Engine
58
Engine Components Removable with Engine in Place
59
Engine Removal and Installation
60
Engine Mounting
66
Engine Installation
67
Engine Disassembly
72
Engine Components Inspection and Service
84
Cylinder Head Cover
84
CMP Sensor
84
Pair Reed Valve
84
Camshaft
85
Cam Chain Tension Adjuster
87
Cam Chain Tensioner
88
Cam Chain Guide
88
Cylinder Head and Valve
88
Clutch
100
Clutch Drive Plate Inspection
100
Clutch Driven Plate Inspection
101
Clutch Spring Inspection
101
Clutch Bearing Inspection
101
Clutch Lifter
102
Clutch Lifter Pin Adjustment
102
Oil Pump
103
Wave Spring Washer Inspection
103
Starter Clutch
104
Generator
104
Gearshift System
105
Gearshift Shaft/Gearshift Arm Disassembly
105
Gearshift Shaft/Gearshift Arm Inspection
105
Gearshift Shaft/Gearshift Arm Resassembly
105
Oil Pressure Regulator
106
Oil Strainer
106
Transmission
107
Transmission Parts Location
109
Cylinder
110
Cylinder Distortion
110
Cylinder Bore
110
Piston and Piston Ring
111
Piston Diameter
111
Piston-To-Cylinder Clearance
111
Piston Pin and Pin Bore
111
Piston Ring-To-Groove Clearance
112
Piston Ring Free End Gap and Piston Ring End Gap
112
Crankcase
113
Gearshift Fork and Gearshift Cam
113
Gearshift Fork-To-Groove Clearance
113
Gearshift for Groove Width
113
Gearshift Fork Thickness
114
Gearshift Cam Bearing and Gearshift Shaft Bearing
114
Oil Jet
117
Plug
118
Balancer Shaft
120
Balancer Shaft Journal Bearing
120
Crankshaft and Conrod
122
Crankshaft Runout
122
Conrod Big End Side Clearance
123
Conrod-Big End Bearing Inspection
123
Conrod-Big End Bearing Selection
123
Crank Pin O.D.
125
Bearing Thickness
125
Crankshaft Journal Bearing
126
Bearing Selection Table
127
Crankcase I.D. Specification
127
Crankshaft Journal O.D. Specification
128
Bearing Thickness Specification
128
Crankshaft Thrust Bearing
129
Crankshaft Thrust Clearance Adjustment
129
Thrust Bearing Selection Table
130
Engine Reassembly
131
Piston and Conrod
132
FI System Diagnosis
164
Precautions in Servicing
166
Electrical Parts
166
Connector/Coupler
166
Fuse
167
Ecm/Various Sensors
167
Electrical Circuit Inspection Procedure
169
Open Circuit Check
169
Continuity Check
170
Short Circuit Check (Wire Harness to Ground)
171
Using the Multi-Circuit Tester
172
FI System Technical Features
173
Injection Time (Injection Volume)
173
Compensation of Injection Time (Volume)
174
Injection Stop Control
174
FI System Parts Location
175
FI System Wiring Diagram
177
ECM Terminal
178
Self-Diagnosis Function
180
User Mode
180
Dealer Mode
181
TPS Adjustment
183
Fail-Safe Function
184
FI System Troubleshooting
186
Customer Complain Analysis
186
Visual Inspection
187
Self-Diagnosis Procedures
188
Self-Diagnosis Reset Procedure
188
Use of SDS Diagnostic Procedures
189
Use of SDS Diagnosis Reset Procedure
190
Show Data When Trouble (Displaing Data at the Time of DTC)
191
Malfunction Code and Defective Condition
192
"C11" (P0340) CMP Sensor Circuit Malfunction
196
"C12" (P0335) CKP Sensor Circuit Malfunction
198
"C13" (P0105-H/L) IAP Sensor Circuit Malfunction
200
"C14" (P0120-H/L) TP Sensor Circuit Malfunction
206
"C15" (P0115-H/L) ECT Sensor Circuit Malfunction
211
"C21" (P0110-H/L) IAT Sensor Circuit Malfunction
215
"C22" (P1450-H/L) AP Sensor Circuit Malfunction
219
Suzuki
GSX-R1000K5
Service Manual
Suzuki GSX-R1000 Service Manual (525 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 29.47 MB
Table of Contents
Foreword Group Index
3
Table of Contents
3
How to Use this Manual
4
Abbreviations Used in this Manual
6
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
Precautions in Servicing
163
Electrical Parts
163
Fuse
164
Ecm/Various Sensors
164
Electrical Circuit Inspection Procedure
166
Using the Multi-Circuit Tester
169
Fi System Technical Features
170
Injection Time (Injection Volume)
170
Compensation of Injection Time (Volume)
171
Injection Stop Control
171
Fi System Parts Location
172
Fi System Wiring Diagram
174
Ecm Terminal
175
Self-Diagnosis Function
177
User Mode
177
Dealer Mode
178
Tps Adjustment
180
Fail-Safe Function
181
Fi System Troubleshooting
183
Customer Complaint Analysis
183
Visual Inspection
184
Self-Diagnostic Procedures
185
Self-Diagnosis Reset Procedure
185
Use of Sds Diagnostic Procedures
186
Use of Sds Diagnosis Reset Procedure
187
Show Data When Trouble (Displaing Data at the Time of Dtc)
188
Malfunction Code and Defective Condition
189
C11" (P0340) Cmp Sensor Circuit Malfunction
193
C12" (P0335) Ckp Sensor Circuit Malfunction
195
C13" (P0105-H/L) Iap Sensor Circuit Malfunction
197
C14" (P0120-H/L) Tp Sensor Circuit Malfunction
203
C15" (P0115-H/L) Ect Sensor Circuit Malfunction
208
C21" (P0110-H/L) Iat Sensor Circuit Malfunction
212
C22" (P1450-H/L) Ap Sensor Circuit Malfunction
216
C23" (P1651-H/L) to Sensor Circuit Malfunction
221
C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354) IGNITION SYSTEM MALFUNCTION
224
C28" (P1655) Stv Actuator Circuit Malfunction
225
C29" (P1654-H/L) Stp Sensor Circuit Malfunction
228
C31" (P0705) Gp Switch Circuit Malfunction
233
C32" (P0201), "C33" (P0202), "C34" (P0203) or "C35" (P0204) PRIMARY FUEL INJECTOR CIRCUIT MALFUNCTION
235
C36" (P1764), "C37" (P1765), "C38" (P1766) or "C39" (P1767) SECONDARY FUEL INJECTOR CIRCUIT MALFUNCTION
237
C41" (P0230-H/L) Fp Relay Circuit Malfunction
239
C42" (P01650) Ig Switch Circuit Malfunction
241
C46" (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION
242
C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction
251
C60" (P0480) Cooling Fan Relay Circuit Malfunction
253
Sensors
255
Cmp Sensor Inspection
255
Cmp Sensor Removal and Installation
255
Ckp Sensor Inspection
255
Ckp Sensor Removal and Installation
255
Iap Sensor Inspection
255
Iap Sensor Removal and Installation
255
Tp Sensor Inspection
255
Tp Sensor Removal and Installation
255
Tps Adjustment
255
Ect Sensor Inspection
256
Ect Sensor Removal and Installation
256
Iat Sensor Inspection
256
Iat Sensor Removal and Installation
256
Ap Sensor Inspection
256
Ap Sensor Removal and Installation
256
To Sensor Inspection
256
To Sensor Removal and Installation
256
Stp Sensor Inspection
257
Stp Sensor Removal and Installation
257
Stp Sensor Adjustment
257
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Suzuki GSX-R1000 Service Manual (460 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 20.7 MB
Table of Contents
Generalwformation
9
Table of Contents
9
Warning/Caution/Note
10
General Precautions
10
Suzuki Gsx-R1000K3 ('03-Model)
12
Serial Number Location
12
FUEL, OIL and ENGINE COOLANT RECOMMENDA Tlon
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
Country and Area Codes
19
Periodic Maintenance
20
Periodic Maintenance Schedule
21
Periodic Maintenance Chart
21
Lubrication Points
23
Maintenance and Tune-Up Procedures
24
Air Cleaner
24
Spark Plug
25
Valve Clearance
27
Engine Oil and Oil Filter
32
Exhaust Control Valve
33
Fuel Line
34
Engine Idle Speed
34
THROTTLE VAL VE SYNCHRONIZA Non
35
Evaporative Emission Control System (E-33 Only)
35
Pair (Air Supply) System
35
Throttle Cable Play
36
Clutch
37
Cooling System
38
Drive Chain
41
Brake
44
Tires
47
Steering
48
Front Fork
48
Rear Suspension
48
Exhaust Pipe Bol Tand Nut
49
Chassis Bolts and Nuts
50
Compression Pressure Check
52
Compression Test Procedure
52
Oil Pressure Check
53
Engine
54
Engine Components Removable with Engine in Place
55
Engine Removal and Installation
56
Engine Removal
56
Engine Installation
63
ENGINE Disassembly
68
Engine Components Inspection and Service
81
Cylinder Head Cover
81
Pair Control Valve
82
Camshaft
82
Cam Chain Tension Adjuster
84
Cam Chain Tensioner
85
Cam Chain Guide
85
Cylinder Head and Valve
85
Clutch
96
Oil Pump
97
Starter Clutch
97
Generator
97
Water Pump
98
Gearshift System
98
Oil Pressure Regulator
99
Oil Strainer
99
Transmission
100
Cylinder
103
Piston and Piston Ring
104
Crankcase
106
Balancer Shaft
113
Balancer Shaft Journal Bearing
113
Crankshaft and Conrod
116
Crankshaft Journal Bearing
120
Crankshaft Thrust Bearing
123
Engine Reassembly
125
Fi System Diagnosis
158
PRECAUTIONS in Servicing
160
Eletrical Parts
160
Fuse
161
Ecmnarious Sensors
161
Electrical Circuit Inspection Procedure
163
Using Testers
166
Fi System Technical Features
167
Injection Time (Injection Volume)
167
Compensation of Injection Time (Volume)
168
Injection Stop Control
168
Injection Timing
169
Self-Diagnosis Function
173
User Mode
173
Dealer Mode
174
Tps Adjustment
176
Fail-Safe Function
177
Fi System Troubleshooting
179
Customer Complaint Analysis
179
Self-Diagnostic Procedures
181
Self-Diagnosis Reset Procedure
181
Malfunction Code and Defective Condition
182
C11" Cmp Sensor Circuit Malfunction
184
C12" Ckp Sensor Circuit Malfunction
186
C13" Lap SENSOR CIRCUIT MALFUNCTION
188
C14" Tp Sensor Circuit Malfunction
191
C15" Ect Sensor Circuit Malfunction
194
"C21" Iat Sensor Circuit Malfunction
196
C22" Ap Sensor Circuit Malfunction
198
C23" to Sensor Circuit Malfunction
201
C24", "C25", "C26" or "C27" IGINTION SYSTEM MALFUNCTION
202
C28" Stv Actua Tor Circuit Malfunction
203
C29" Stp Sensor Circuit Malfunction
205
C31" Gear Position (Gp) Switch Circuit Malfunction
208
C32", "C33", "C34" or "C35" FUEL INJECTOR CIRCUIT MALFUNCTION
209
"C41" Fp Relay Circuit Malfunction
211
C42" IG SWITCH CIRCUIT Malfunctlon
211
C46" Excv Actuator Circuit Malfunction
212
Ckp Sensor Inspection
218
Ckp Sensor Removal and Installation
218
Cmp Sensor Inspection
218
CMP SENSOR REMOVAL and Installatlon
218
Lap SENSOR INSPECTION
218
Sensors
218
Tp Sensor Inspection
218
Tp Sensor Removal and Installation
218
Tps Adjustment
218
Ap Sensor Inspection
219
Ap Sensor Removal and Installation
219
Ect Sensor Inspection
219
Ect Sensor Removal and Installation
219
Ia Tsensor Inspection
219
Iat Sensor Removal and Installation
219
To Sensor Inspection
219
To Sensor Removal and Installation
219
Stp Sensor Adjustment
220
Stp Sensor Inspection
220
Stp Sensor Removal and Installation
220
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