Suzuki GSX-R 1000 Service Manual: Engine assembly removal
Before taking the engine out of the frame, wash the
engine using a steam cleaner. Engine removal is
sequentially explained in the following steps:
- remove the side cowlings. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Disconnect the battery (–) lead wire (1).
- Jack up the motorcycle and fix it for safety.
- Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
- Drain engine coolant. Refer to “engine oil and filter replacement” in
section 0b .
- Lift and support the fuel tank. Refer to “fuel tank
removal and installation” in section 1g (page 1g-
9).
- Remove the air cleaner box. Refer to “air cleaner box removal and
installation” .
- Remove the throttle body assembly. Refer to
“throttle body removal and installation” (page 1d-
10).
- Remove the oil cooler and hoses. Refer to “oil cooler / oil cooler hose
removal and installation” in section 1e .
- Remove the radiator assembly. Refer to “radiator / cooling fan motor
removal and installation” in section 1f .
- Disconnect the water/air bleed hose (2) and radiator
inlet hose (3).
- Remove the horn (4) and radiator heat guard (5).
- Remove the radiator/oil cooler mounting bracket (6).
- Remove the exhaust system components. Refer to “muffler / muffler
chamber / exhaust pipe removal and installation” in section 1k .
- Remove the clamp (7).
- Disconnect the oil pressure switch lead wire coupler
(8), generator lead wire coupler (9) and ect sensor
coupler (10).
- Disconnect the gp switch lead wire coupler (11).
- Disconnect the starter motor lead wire (12) and
engine ground lead wire (13).
- Disconnect the ckp sensor lead wire coupler (14).
- Remove the crankcase breather (pcv) hose (15).
- Disconnect the pair solenoid valve coupler (16).
- Disconnect the cmp sensor lead wire coupler (17)
and ignition coil couplers (18).
- Remove the ignition coils.
Caution
- do not remove the ignition coil before
disconnecting its coupler.
- Do not pry up the ignition coil/plug cap
with a screwdriver or a bar to avoid its
damage.
- Be careful not to drop the ignition coil/plug
cap to prevent its short or open circuit.
|
- Remove the engine sprocket cover (19). Refer to “engine sprocket removal
and installation” in section 3a .
- Remove the dowel pins and clutch push rod (20).
- Remove the engine sprocket (21). Refer to “engine sprocket removal and
installation” in section 3a .
- Support the engine using an engine jack.
- Loosen the engine mounting pinch bolts (22) (rh).
- Remove the engine mounting bolts (23) (rh).
- Remove the engine mounting bolts (24) (lh).
- Remove the engine mounting nut (25).
- Remove the engine mounting thrust adjuster locknut
(26) with the special tool.
- Loosen the engine mounting thrust adjuster (27)
fully.
Special tool
(a): 09940–14990 (engine mounting
adjust
wrench)
Note
do not remove the engine mounting bolt at
this stage. |
- Remove the engine mounting nut (28).
- Loosen the engine mounting thrust adjuster lock-nut
(29) with the special tool.
- Loosen the engine mounting thrust adjuster (30)
fully.
Special tool
(a): 09940–14990 (engine mounting
adjust
wrench)
Note
do not remove the engine mounting bolt at
this stage. |
- Remove the engine mounting bolts and gradually
lower the front side of the engine. Then, take off the
drive chain from the driveshaft.
- Remove the engine assembly.
When replacing the throttle body assembly or tp sensor
with a new one or reinstalling the tp sensor, reset the
tp learned value in the following procedures:
Note
keep the throttle valves ...
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
before installing the engine, install the collars (1).
Before installing the en ...
Other materials:
Front brake light switch inspection
Inspect the front brake light switch in the following
procedures:
disconnect the front brake light switch coupler (1).
Inspect the front brake light switch for continuity with
the tester.
If any abnormality is found, replace the front brake light switch with a new
one. Re ...
General description
Fuel injection system description
Fuel system
The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel
filter (3), fuel feed hose (4), fuel delivery pipes
(5) including fuel injectors (6) and (7), fuel pressure regulator (8). There is
no fuel return hose. The fuel in the fu ...
Component location
Electrical components location
Ignition switch/immobilizer antenna
Iat sensor
Secondary fuel injector
Primary fuel injector
Iap sensor
Evap system purge control solenoid valve
Fuel pump relay
Turn signal/side-stand relay
Cooling fan relay
Ect ...