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Suzuki GSX-R 1000 Service Manual: General precautions


  • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.
  •  When 2 or more persons work together, pay attention to the safety of each other.
  •  When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
  •  When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material manufacturers instructions.
  •  Never use gasoline as cleaning solvent.
  • To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled.
  •  After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.

 

Caution


  • If parts replacement is necessary, replace the parts with suzuki genuine parts or their equivalent.
  •  When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  •  Be sure to use special tools when instructed.
  •  Make sure that all parts used in reassembly are clean. Lubricate them when specified.
  •  Use the specified lubricant, bond or sealant.
  •  When removing the battery, disconnect the negative () cable first and then the positive (+) cable.
  •  When reconnecting the battery, connect the positive (+) cable first and then the negative () cable, and replace the terminal cover on the positive (+) terminal.
  •  When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative () cable the battery.
  •  When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
  •  Whenever you remove oil seals, gaskets, packing, o-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.
  • Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
  •  Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
  •  After reassembling, check parts for tightness and proper operation.
  •  To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires.
  •  To protect earths natural resources, properly dispose of used motorcycle and parts.
Warning / caution / note
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to t ...

Precautions for electrical circuit service
When handling the electrical parts or servicing fi system, observe the following points for the safety of the systems. ...

Other materials:

Iap sensor removal and installation
Removal Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).  Disconnect the coupler (1) and vacuum hose (2).  Remove the iap sensor (3) from the air cleaner box. Installation Install the iap sensor in the reverse ord ...

Rear brake master cylinder parts inspection
Refer to rear brake master cylinder disassembly and assembly . Master cylinder Inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust boot ...

Throttle cable routing diagram
Throttle cable no. 1 Throttle cable no. 2 Clutch cablev Front brake hose Pass the throttle cables in front of the front brake hose. Pass the clutch cable above the right air intake pipe. Clamp the clutch cable at the white taping point and m ...

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