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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:

Oil cooler / oil cooler hose inspection and cleaning
Refer to exterior parts removal and installation in section 9d . Oil cooler hose inspection Inspect the oil cooler hoses for any damage and oil leakage. If any defects are found, replace the oil cooler hose with a new one. Oil cooler inspection Remove the oil cooler guard (1). ...

Rear brake master cylinder components
Reservoir cap Plate Diaphragm Reservoir tank Reservoir hose Brake hose Brake hose union bolt Brake hose connector Master cylinder Spring Piston/cup set Push rod Dust boot 23 Nm (2.3 Kgf-m, 16.5 Lbf-ft) 10 Nm ...

Brake pad
Front Rear Inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1. If a pad is worn to the grooved wear limit line, it must be replaced with a new one. After replacing either the front or rear brake pads, the brake lever or pedal must be ...

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