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Suzuki GSX-R 1000 Service Manual: Muffler / muffler chamber / exhaust pipe removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Exhaust system / Repair instructions / Muffler / muffler chamber / exhaust pipe removal and installation

Removal

  1. Loosen the muffler connecting bolts (1).
  2.  Remove the mufflers (2) by removing the mounting bolt and nut (3).
Note

support the muffler to prevent it from falling.

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
  2.  Lift and support the fuel tank with the prop stay.

    Refer to “fuel tank removal and installation” in section 1g .

  3.  Disconnect the ho2 sensor coupler (4).

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Remove the muffler chamber heat guard no. 2 (5).

    (Rh only)

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Loosen the muffler chamber connecting bolt (6).
  2.  Remove the muffler chamber (7).

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Remove the muffler chamber heat guard no. 1 (8) And ho2 sensor (9) from the muffler chamber.
Caution

  •  be careful not to expose the ho2 sensor to an excessive shock.
  •  Be careful not to twist or damage the ho2 sensor lead wires.

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Remove the excv cables (10). Refer to “excv cable removal and installation” .

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Move the radiator and oil cooler forward. Refer to “radiator inspection and cleaning” in section 1f .
  2. Remove the exhaust pipe assembly by removing the exhaust pipe bolts.
Caution

take care not to bend the radiator/oil cooler fins.

 

Note

support the exhaust pipe assembly to prevent it from falling.

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


  1. Remove the exhaust pipe gaskets (11).

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


Installation

Installation is in the reverse order of removal. Pay attention to the following points:

Tightening torque ho2 sensor (a): 25 n·m (2.5 Kgf-m, 18.0 Lbf-ft)

Caution

  •  be careful not to expose the ho2 sensor to an excessive shock.
  •  Do not use an impact wrench when installing the ho2 sensor.
  •  Be careful not to twist or damage the ho2 sensor lead wires.
  •  Do not apply oil or other materials to the sensor air holes.

Suzuki GSX-R. Muffler / muffler chamber / exhaust pipe removal and installation


Caution

replace the gaskets and connectors with new ones.

 

Note

when installing a new connector, remove all of the old sealer. Apply the exhaust gas sealer to both the inside and outside of the new connector.

: Muffler seal (muffler
seal loctite 5920 (commercially available) or equivalent)

Excva adjustment
Inspect the excva operation and adjust it if necessary in the following steps: Step 1 Set the excva to the adjustment position. Refer to “excv cable removal and installation” (page 1k- 6). ...

Exhaust system inspection
Inspect the exhaust pipe, muffler chamber and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe, muffler chamber or muffler with a ...

Other materials:

Water pump related parts inspection
Refer to “water pump disassembly and assembly” . Mechanical seal Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows indications of leakage. Oil seal Visually inspect the oil seal for damage, with p ...

Battery visual inspection
Inspect the battery in the following procedures:  remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of th ...

Rear brake master cylinder disassembly and assembly
Refer to “rear brake master cylinder assembly removal and installation” . Disassembly Disconnect the reservoir hose (1).  Remove the lock-nut (2). Remove the brake hose connector (3) and o-ring (4). Special tool : 09900–06108 (snap ring remover (close type)) Pu ...

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