Suzuki GSX-R 1000 Service Manual: Fuel pump disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Engine / Fuel system / Repair instructions / Fuel pump disassembly and assembly

Disassembly

Remove the fuel tank. Refer to “fuel tank removal and installation” .
Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.

Spilled gasoline should be wipe off immediately.
Keep away from fire or spark.
Work in a well-ventilated area.

Suzuki GSX-R. Disassembly

Disconnect the lead wires (2).

Suzuki GSX-R. Disassembly

Remove the fuel level gauge (3).

Suzuki GSX-R. Disassembly

Remove the fuel pressure regulator assembly (4).

Caution

never remove the fuel pressure regulator (5) from the holder.

Suzuki GSX-R. Disassembly

Remove the o-ring (6) and fuel pump case (7).

Suzuki GSX-R. Disassembly

Remove the o-ring (8) and joint (9).
Remove the o-ring (10) and lead wires (11).

Suzuki GSX-R. Disassembly

Remove the fuel mesh filter (12).
Remove the fuel pump (13).

Suzuki GSX-R. Disassembly

Assembly

Refer to “fuel mesh filter inspection and cleaning” .

Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points:

Caution

to prevent fuel leakage, the bushing and o-ring must be replaced with new ones.
Apply engine oil lightly to the o-rings.

Suzuki GSX-R. Assembly

Caution

connect all lead wires securely so as not to cause contact failure.

Suzuki GSX-R. Assembly

Fuel pump (+) lead wire (y/r)
Fuel level gauge (+) lead wire (r/b)
Fuel pump (–) lead wire (b/w)
Fuel level gauge (–) lead wire (b/w)

Install a new o-ring and apply grease to it.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

The o-ring
must be replaced with a new one to prevent fuel leakage.

Suzuki GSX-R. Assembly

When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending of numbers.

Tightening torque fuel pump mounting bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Assembly

Fuel pump components

Fuel level gauge Fuel pressure regulator assembly O-ring Joint Fuel pump Fuel pump case Fuel mesh filter 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) Appl ...

Fuel mesh filter inspection and cleaning

Inspect the fuel mesh filter in the following procedures: remove the fuel mesh filter. Refer to “fuel pump disassembly and assembly” . If the fuel mesh filter is clogged with fore ...

Other materials:

Special tools and equipment
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Detected condition and possible cause Detected condition Possible cause C29 Output voltage is not within the following range. Difference between actual throttle opening and opening calculated by ecm is larger than specified value. 0.15 V ≤ Sensor ...

Starter motor inspection
Refer to “starter motor disassembly and assembly” . Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length “a” of the carbon brushes using a v ...