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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

  1. Remove the fuel tank. Refer to fuel tank removal and installation .
  2.  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


  1. Disconnect the lead wires (2).

Suzuki GSX-R. Disassembly


  1. Remove the fuel level gauge (3).

Suzuki GSX-R. Disassembly


  1. Remove the fuel pressure regulator assembly (4).
Caution

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

Suzuki GSX-R. Disassembly


Suzuki GSX-R. Disassembly


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

Suzuki GSX-R. Disassembly


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

Suzuki GSX-R. Disassembly


  1. Remove the fuel mesh filter (12).
  2.  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


Suzuki GSX-R. Assembly


Caution

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

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


  1. Fuel pump (+) lead wire (y/r)
  2. Fuel level gauge (+) lead wire (r/b)
  3. Fuel pump () lead wire (b/w)
  4. Fuel level gauge () lead wire (b/w)

: Grease 9900025010 (suzuki
super grease a or equivalent)

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

Suzuki GSX-R. Assembly


Tightening torque fuel pump mounting bolt (a): 10 nm (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 Nm (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:

If a collision is imminent, do something
Many riders fear locking up their brakes or haven't learned to swerve to avoid an accident. Many inexperienced riders (and too many seasoned riders) use only their rear brake in an emergency, resulting in unnecessary impacts in some cases and unnecessarily high impact speeds in other case ...

Ect sensor removal and installation
Removal Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .  Drain engine coolant. Refer to cooling system inspection in section 0b .  Disconnect the coupler and remove the ect sensor (1). Caution take special care ...

Emission control warranty
Suzuki motor corporation warrants to the ultimate purchaser and each subsequent purchaser that this vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. Emission standards applicable at the time of manufacture, and that it is free from defects in materi ...

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