Suzuki GSX-R 1000 Service Manual: Engine assembly removal
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 “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Disconnect the battery (–) lead wire (1).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.27.gif)
- Jack up the motorcycle and fix it for safety.
- Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
- Drain engine coolant. Refer to “engine oil and filter replacement” in
section 0b .
- Lift and support the fuel tank. Refer to “fuel tank
removal and installation” in section 1g (page 1g-
9).
- Remove the air cleaner box. Refer to “air cleaner box removal and
installation” .
- Remove the throttle body assembly. Refer to
“throttle body removal and installation” (page 1d-
10).
- Remove the oil cooler and hoses. Refer to “oil cooler / oil cooler hose
removal and installation” in section 1e .
- Remove the radiator assembly. Refer to “radiator / cooling fan motor
removal and installation” in section 1f .
- Disconnect the water/air bleed hose (2) and radiator
inlet hose (3).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.35.jpg)
- Remove the horn (4) and radiator heat guard (5).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.36.jpg)
- Remove the radiator/oil cooler mounting bracket (6).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.37.jpg)
- Remove the exhaust system components. Refer to “muffler / muffler
chamber / exhaust pipe removal and installation” in section 1k .
- Remove the clamp (7).
- Disconnect the oil pressure switch lead wire coupler
(8), generator lead wire coupler (9) and ect sensor
coupler (10).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.38.jpg)
- Disconnect the gp switch lead wire coupler (11).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.39.jpg)
- Disconnect the starter motor lead wire (12) and
engine ground lead wire (13).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.40.jpg)
- Disconnect the ckp sensor lead wire coupler (14).
- Remove the crankcase breather (pcv) hose (15).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.44.jpg)
- Disconnect the pair solenoid valve coupler (16).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.46.jpg)
- Disconnect the cmp sensor lead wire coupler (17)
and ignition coil couplers (18).
- Remove the ignition coils.
Caution
- do not remove the ignition coil before
disconnecting its coupler.
- Do not pry up the ignition coil/plug cap
with a screwdriver or a bar to avoid its
damage.
- Be careful not to drop the ignition coil/plug
cap to prevent its short or open circuit.
|
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.47.jpg)
- Remove the engine sprocket cover (19). Refer to “engine sprocket removal
and installation” in section 3a .
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.51.jpg)
- Remove the dowel pins and clutch push rod (20).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.52.jpg)
- Remove the engine sprocket (21). Refer to “engine sprocket removal and
installation” in section 3a .
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.53.jpg)
- Support the engine using an engine jack.
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.41.gif)
- Loosen the engine mounting pinch bolts (22) (rh).
- Remove the engine mounting bolts (23) (rh).
- Remove the engine mounting bolts (24) (lh).
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.54.jpg)
- Remove the engine mounting nut (25).
- Remove the engine mounting thrust adjuster locknut
(26) with the special tool.
- Loosen the engine mounting thrust adjuster (27)
fully.
Special tool
(a): 09940–14990 (engine mounting
adjust
wrench)
Note
do not remove the engine mounting bolt at
this stage. |
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.55.jpg)
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.56.jpg)
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.45.gif)
- Remove the engine mounting nut (28).
- Loosen the engine mounting thrust adjuster lock-nut
(29) with the special tool.
- Loosen the engine mounting thrust adjuster (30)
fully.
Special tool
(a): 09940–14990 (engine mounting
adjust
wrench)
Note
do not remove the engine mounting bolt at
this stage. |
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.58.jpg)
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.59.jpg)
![Suzuki GSX-R. Engine assembly removal](images/books/111/7/index.49.gif)
- Remove the engine mounting bolts and gradually
lower the front side of the engine. Then, take off the
drive chain from the driveshaft.
- Remove the engine assembly.
When replacing the throttle body assembly or tp sensor
with a new one or reinstalling the tp sensor, reset the
tp learned value in the following procedures:
Note
keep the throttle valves ...
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 en ...
Other materials:
Inspecting the drive chain
When inspecting the chain, look
for the following:
loose pins
damaged rollers
dry or rusted links
kinked or binding links
excessive wear
improper chain adjustment
If you find anything wrong with the
drive chain condition or adjustment,
correct the pr ...
Steering system inspection
Inspect steering system
initially at 1 000 km (600 miles, 2 months) and every
12 000 km (7 500 miles, 24 months) thereafter
Steering should be adjusted properly for smooth turning
of handlebars and safe running. Overtighten steering
prevents smooth turning of the handlebars and too loose
steer ...
Drive mode selector inspection
Inspect the drive mode selector in the following procedures:
set up the sds tool. (Refer to the sds operation manual for
further details.)
Turn the ignition switch on.
Click “data monitor”.
Make sure each of “driving mode selection” on the monitor is
indicated ...