Suzuki GSX-R 1000 Service Manual: Engine assembly installation
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
- before installing the engine, install the collars (1).

- Before installing the engine, install the engine
mounting thrust adjusters (2).

- Gradually raise the rear side of the engine assembly,
and then put the drive chain on the driveshaft.
Caution
be careful not to catch the wiring harness
between the frame and the engine. |

- Install all engine mounting bolts and tighten them
temporarily.
- Tighten the engine mounting thrust adjusters (2) to the
specified torque.
Tightening torque
engine mounting thrust adjuster (a): 23 n·m (2.3
Kgf-m, 16.5 Lbf-ft)


- Tighten the engine mounting thrust adjuster lock-nuts
(3) to the specified torque with the special tool.
Tightening torque
engine mounting thrust adjuster lock-nut (b): 45
n·m (4.5 Kgf-m, 32.5 Lbf-ft)
Special tool
(a): 09940–14990 (engine mounting
adjust
wrench)


- Tighten all engine mounting bolts and nuts to the
specified torque, as shown in the following illustration
Note
the engine mounting nuts are self-locking.
Once the nuts have been removed, they are
no longer of any use. |
- Tighten the engine mounting pinch bolt to the
specified torque, as shown in the following illustration.

- Collar
- Engine mounting thrust adjuster
- Engine mounting thrust adjuster lock-nut
- Engine mounting bolt (220 mm)
- Engine mounting bolt (45 mm)
- Engine mounting bolt (55 mm)
- Engine mounting nut
- Engine mounting pinch bolt
23
N·m (2.3 Kgf-m, 16.5 Lbf-ft)
45 N·m (4.5
Kgf-m, 32.5 Lbf-ft)
75 N·m (7.5
Kgf-m, 54.0 Lbf-ft)
55 N·m (5.5
Kgf-m, 40.0 Lbf-ft)
|
- Install the engine sprocket. Refer to “engine sprocket removal and
installation” in section 3a .
- Install the exhaust pipe assembly and muffler. Refer to “muffler /
muffler chamber / exhaust pipe removal and installation” in section 1k .
- Install the radiator. Refer to “radiator / cooling fan motor removal
and installation” in section 1f .
- Install the throttle body. Refer to “throttle body removal and
installation” .
- Install the air cleaner box. Refer to “air cleaner box removal and
installation” .
- After remounting the engine, route the wiring harness, cable and hoses
properly. Refer to “wiring harness routing diagram” in section 9a ,
“throttle cable routing diagram” and “water hose routing diagram” in
section 1f .
- Pour engine coolant and engine oil. Refer to “cooling system
inspection” in section 0b and “engine oil and filter replacement” in
section 0b .
- After finishing the engine installation, check the
following items.
- Throttle cable play refer to “throttle cable play inspection and
adjustment” in section 0b .
- Throttle valve synchronization
refer to “throttle valve synchronization” (page 1d-
16).
- Clutch cable play refer to “clutch cable play inspection and
adjustment” in section 0b .
- Drive chain slack refer to “drive chain inspection and adjustment” in
section 0b .
- Engine oil and coolant leakage refer to “cooling circuit inspection” in
section 1f .
Before taking the engine out of the frame, wash the
engine using a steam cleaner. Engine removal is
sequentially explained in the following steps:
remove the side cowlings. Refer to “exter ...
It is unnecessary to remove the engine assembly from
the frame when servicing the cylinder head cover and
camshafts.
Note
before servicing the engine top side
components (until camshaf ...
Other materials:
Clutch lever position switch inspection
Inspect the clutch lever position switch in the following
procedures:
disconnect the clutch lever position switch lead
wires (1).
Inspect the clutch lever position switch for continuity
with the tester.
If any abnormality is found, replace the switch with a
new one.
S ...
DTC “c62” (p0443): evap system purge
control solenoid valve circuit malfunction
(e-33 only)
Detected condition and possible cause
Detected condition
Possible cause
Evap system purge control valve voltage is not input to
ecm.
Evap system purge control valve circuit open or short.
Evap system purge control valve malfunction.
Ecm malfunction. ...
Wiring harness routing diagram
Wiring harness no. 2
Tapping clamp
: insert the clamp from the front side. Place the turn signal
and position light couplers in front of the clamp.
Steel clamp
: clamp the wiring harness at the blue taping point. Bend
the steel clamps to the front side.
...