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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:

Fuel pump relay inspection
Refer to electrical components location in section 0a . Inspect the fuel pump relay in the following procedures:  remove the frame covers. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Remove the fuel pump relay (1). First, check f ...

Heated oxygen sensor (ho2s) removal and installation
Removal Do not remove the ho2 sensor while it is hot.   Caution  be careful not to expose the ho2 sensor to excessive shock.  Do not use an impact wrench when removing or installing the ho2 sensor.  Be careful not to twist or damage t ...

Clutch removal
Drain engine oil. Refer to engine oil and filter replacement in section 0b .  Lift and support the fuel tank with the prop stay. Refer to fuel tank removal and installation in section 1g .  Disconnect the ckp sensor coupler (1). Remove the clutch cover (2). ...

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