Suzuki GSX-R 1000 Service Manual: Fuel tank removal and installation
Removal
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- Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
- Take out the fuel tank prop stay (1).
- Remove the bolts.
- Lift and support the fuel tank with the prop stay.
- Disconnect the fuel pump lead wire coupler (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. |
- Disconnect the fuel tank drain hose (4).
- Disconnect the surge hose (5). (For e-33)
- disconnect the fuel tank breather hose. (Except for e-33)
- Remove the fuel tank by removing its bracket bolt (6).
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
N·m (1.0 Kgf-m, 7.0 Lbf-ft)
Appl ...
Other materials:
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 adhesive surface before adhering
the velcro fastenings.
Insert
to the bracket.
Apply
...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Rear brake components”
Special tool
...
Valve seat repair
The valve seats (1) for both the intake and exhaust
valves are machined to three different angles. The seat
contact surface is cut at 45°.
Intake valve
Exhaust valve
Caution
the valve seat contact area must be
inspected after e ...