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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:

Steering / steering damper related parts inspection
Refer to steering / steering damper removal and installation . Inspect the removed parts for the following abnormalities: Steering stem Distortion of the steering stem and brackets. Bearing Bearing wear or damage  abnormal bearing noise  race wear or damage &nbs ...

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

Starting the engine
Before attempting to start the engine, make sure:  The transmission is in neutral.  The engine stop switch is in the "" position. Note: this motorcycle has a starter interlock system for the ignition and starter circuit. The engine can only be started if:   ...

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