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Suzuki GSX-R 1000 Service Manual: Engine components removable with the engine in place

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Engine components removable with the engine in place

Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component.

Center of engine

Item

Removal

Inspection

Installation

Air cleaner element Refer to “air cleaner element removal and installation” . Refer to “air cleaner element inspection” in section 0b . Refer to “air cleaner element removal and installation” .
Pair control solenoid valve Refer to “pair control solenoid valve removal and installation” in section 1b . Refer to “pair system inspection” in section 1b . Refer to “pair control solenoid valve removal and installation” in section 1b .
Cylinder head cover Refer to “engine top side disassembly” .

Refer to “engine top side assembly” .
Camshafts Refer to “engine top side disassembly” . Refer to “camshaft inspection” . Refer to “engine top side assembly” .
Throttle body Refer to “throttle body removal and installation” . Refer to “camshaft inspection” . Refer to “throttle body removal and installation” .
Thermostat Refer to “thermostat removal and installation” in section 1f . Refer to “thermostat inspection” in section 1f . Refer to “thermostat removal and installation” in section 1f .
Crankcase breather cover Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b . Refer to “crankcase breather (pcv) cover inspection” in section 1b . Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b .
Starter motor Refer to “starter motor removal and installation” in section 1i . Refer to “starter motor inspection” in section 1i . Refer to “starter motor removal and installation” in section 1i .
Oil filter Refer to “engine oil and filter replacement” in section 0b .

Refer to “engine oil and filter replacement” in section 0b .
Oil cooler Refer to “oil cooler / oil cooler hose removal and installation” in section 1e .

Refer to “oil cooler / oil cooler hose removal and installation” in section 1e .
Exhaust pipe/muffler Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k . Refer to “exhaust system inspection” in section 1k . Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .

Engine right side

Item

Removal

Inspection

Installation

Cam chain tension adjuster Refer to “engine top side disassembly” . Refer to “cam chain tension adjuster inspection” . Refer to “engine top side assembly” .
Clutch cover Refer to “clutch removal” in section 5c .

Refer to “clutch installation” in section 5c .
Clutch plates Refer to “clutch removal” in section 5c . Refer to “clutch parts inspection” in section 5c . Refer to “clutch installation” in section 5c .
Clutch sleeve hub Refer to “clutch removal” in section 5c .

Refer to “clutch installation” in section 5c .
Primary driven gear Refer to “clutch removal” in section 5c . Refer to “clutch parts inspection” in section 5c . Refer to “clutch installation” in section 5c .
Oil pump drive sprocket Refer to “engine bottom side disassembly” .

Refer to “engine bottom side assembly” (page 1d- 56).
Gearshift shaft Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b . Refer to “gearshift linkage inspection” in section 5b . Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .
Ckp sensor rotor/cam chain drive sprocket Refer to “engine bottom side disassembly” .

Refer to “engine bottom side assembly” (page 1d- 56).
Cam chain tensioner Refer to “engine bottom side disassembly” . Refer to “cam chain tensioner inspection” . Refer to “engine bottom side assembly” (page 1d- 56).
Ckp sensor Refer to “ckp sensor removal and installation” in section 1c . Refer to “ckp sensor inspection” in section 1c . Refer to “ckp sensor removal and installation” in section 1c .
Starter idle gear Refer to “starter clutch removal and installation” in section 1i .

Refer to “starter clutch removal and installation” in section 1i .
Starter clutch Refer to “starter clutch removal and installation” in section 1i . Refer to “starter clutch inspection” in section 1i . Refer to “starter clutch removal and installation” in section 1i .
Starter torque limiter Refer to “starter torque limiter removal and installation” in section 1i . Refer to “starter torque limiter inspection” in section 1i . Refer to “starter torque limiter removal and installation” in section 1i .

Engine left side

Item

Removal

Inspection

Installation

Speed sensor Refer to “speed sensor removal and installation” in section 9c . Refer to “speed sensor inspection” in section 9c . Refer to “speed sensor removal and installation” in section 9c .
Engine sprocket Refer to “engine sprocket removal and installation” in section 3a . Refer to “drive chain related parts inspection” in section 3a . Refer to “engine sprocket removal and installation” in section 3a .
Drive chain Refer to “drive chain replacement” in section 3a . Refer to “drive chain inspection and adjustment” in section 0b . Refer to “drive chain replacement” in section 3a .
Gear position switch Refer to “gear position (gp) switch removal and installation” in section 5b . Refer to “gear position (gp) switch inspection” in section 5b . Refer to “gear position (gp) switch removal and installation” in section 5b .
Generator cover Refer to “generator removal and installation” in section 1j . Refer to “generator removal and installation” in section 1j .
Generator rotor Refer to “generator removal and installation” in section 1j . Refer to “generator removal and installation” in section 1j .
Water pump Refer to “water pump removal and installation” in section 1f . Refer to “water pump related parts inspection” in section 1f . Refer to “water pump removal and installation” in section 1f .
Oil pressure switch Refer to “oil pressure switch removal and installation” in section 1e . Refer to “oil pressure indicator inspection” in section 9c . Refer to “oil pressure switch removal and installation” in section 1e .
Repair instructions
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Air cleaner element removal and installation
Removal Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Remove the air cleaner box cover (1). Remove the air cleaner ...

Other materials:

Brake system inspection
Inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect brake hose and brake fluid every 6 000 km (4 000 miles, 12 months) The brake system of this motorcycle is filled with a glycol-based brake flui ...

DTC “c44” (p0130/p0135): ho2 sensor (ho2s) circuit malfunction
Detected condition and possible cause Detected condition Possible cause C44/P0130 Ho2 sensor output voltage is not input to ecm during engine operation and running condition. Sensor voltage > 1.0 V Ho2 sensor circuit is open or shorted to the po ...

Fuel pressure inspection
Keep away from fire or spark. Spilled gasoline should be wiped off immediately. Work in a well-ventilated area. Inspect the fuel pressure in the following procedures:  lift and support the fuel tank. Refer to “fuel tank removal and installati ...

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