Suzuki GSX-R 1000 Service Manual: 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.
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- Disconnect the lead wires (2).
- Remove the fuel level gauge (3).
- Remove the fuel pressure regulator assembly (4).
| Caution never remove the fuel pressure regulator (5) from the holder. |
- Remove the o-ring (6) and fuel pump case (7).
- Remove the o-ring (8) and joint (9).
- Remove the o-ring (10) and lead wires (11).
- Remove the fuel mesh filter (12).
- Remove the fuel pump (13).
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
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| Caution connect all lead wires securely so as not to cause contact failure. |
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- 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. |
- 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)
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:
Specifications
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Rear view mirror construction”
Reference: for the tightening torque of fastener not specified in this
section, refer to “tightening torque list” in section 0c . ...
Conrod crank pin bearing inspection and
selection
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Inspection
Inspect the bearing surfaces for any signs of fusion,
pitting, burn or flaws. If any, replace them with a
specified set of bearings.
Place the plastigauge axially along ...
Pair system inspection
Pair hose
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Inspect the pair hoses for wear or damage. If it is worn or da ...