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Suzuki GSX-R 1000 Service Manual: Fuel tank removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Fuel system / Repair instructions / Fuel tank removal and installation

Removal


  • Keep away from fire or spark.
  •  Spilled gasoline should be wiped off immediately.
  •  Work in a well-ventilated area.
  1. Remove the front seat. Refer to exterior parts removal and installation in section 9d (page 9d- 6).
  2.  Take out the fuel tank prop stay (1).

Suzuki GSX-R. Removal


  1. Remove the bolts.

Suzuki GSX-R. Removal


  1. Lift and support the fuel tank with the prop stay.

Suzuki GSX-R. Removal


  1. Disconnect the fuel pump lead wire coupler (2).
  2.  Place a rag under the fuel feed hose (3) and disconnect the fuel feed hose from the fuel tank.
Caution

when removing the fuel tank, do not leave the fuel feed hose on the fuel pump side.

  1. Disconnect the fuel tank drain hose (4).
  2.  Disconnect the surge hose (5). (For e-33)
  3.  disconnect the fuel tank breather hose. (Except for e-33)

Suzuki GSX-R. Removal


  1. Remove the fuel tank by removing its bracket bolt (6).

Suzuki GSX-R. Removal


Installation

Install the fuel tank in the reverse order of removal.

Pay attention to the following point:

Note

connect the fuel feed hose to the fuel pump until it locks securely (a click is heard).

Fuel tank construction
Fuel tank heat shield : aluminum film side should face the engine side. Fuel tank front cover Fuel tank front bracket Velcro fastenings : clean the adhesiv ...

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 ...

Other materials:

Air cleaner
The air cleaner element must be kept clean to provide good engine power and g1as mileage. If you use your motorcycle under normal low-stress conditions, you should service the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the ...

Front brake disc inspection
Brake disc thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (a): 0990020205 (micrometer (0 25 mm)) Brake disc thickness service ...

Cam chain tension adjuster inspection
The cam chain tension adjuster is maintained to proper tension automatically.  Remove the cam chain tension adjuster. Refer to engine top side disassembly .  Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body unt ...

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