Suzuki GSX-R 1000 Service Manual: Engine components removable with the engine in place

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Engine components removable with the engine in place

Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component.

Center of engine

Item	Removal	Inspection	Installation
Air cleaner element	Refer to “air cleaner element removal and installation” .	Refer to “air cleaner element inspection” in section 0b .	Refer to “air cleaner element removal and installation” .
Pair control solenoid valve	Refer to “pair control solenoid valve removal and installation” in section 1b .	Refer to “pair system inspection” in section 1b .	Refer to “pair control solenoid valve removal and installation” in section 1b .
Cylinder head cover	Refer to “engine top side disassembly” .	—	Refer to “engine top side assembly” .
Camshafts	Refer to “engine top side disassembly” .	Refer to “camshaft inspection” .	Refer to “engine top side assembly” .
Throttle body	Refer to “throttle body removal and installation” .	Refer to “camshaft inspection” .	Refer to “throttle body removal and installation” .
Thermostat	Refer to “thermostat removal and installation” in section 1f .	Refer to “thermostat inspection” in section 1f .	Refer to “thermostat removal and installation” in section 1f .
Crankcase breather cover	Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b .	Refer to “crankcase breather (pcv) cover inspection” in section 1b .	Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b .
Starter motor	Refer to “starter motor removal and installation” in section 1i .	Refer to “starter motor inspection” in section 1i .	Refer to “starter motor removal and installation” in section 1i .
Oil filter	Refer to “engine oil and filter replacement” in section 0b .	—	Refer to “engine oil and filter replacement” in section 0b .
Oil cooler	Refer to “oil cooler / oil cooler hose removal and installation” in section 1e .	—	Refer to “oil cooler / oil cooler hose removal and installation” in section 1e .
Exhaust pipe/muffler	Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .	Refer to “exhaust system inspection” in section 1k .	Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .

Engine right side

Item	Removal	Inspection	Installation
Cam chain tension adjuster	Refer to “engine top side disassembly” .	Refer to “cam chain tension adjuster inspection” .	Refer to “engine top side assembly” .
Clutch cover	Refer to “clutch removal” in section 5c .	—	Refer to “clutch installation” in section 5c .
Clutch plates	Refer to “clutch removal” in section 5c .	Refer to “clutch parts inspection” in section 5c .	Refer to “clutch installation” in section 5c .
Clutch sleeve hub	Refer to “clutch removal” in section 5c .	—	Refer to “clutch installation” in section 5c .
Primary driven gear	Refer to “clutch removal” in section 5c .	Refer to “clutch parts inspection” in section 5c .	Refer to “clutch installation” in section 5c .
Oil pump drive sprocket	Refer to “engine bottom side disassembly” .	—	Refer to “engine bottom side assembly” (page 1d- 56).
Gearshift shaft	Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .	Refer to “gearshift linkage inspection” in section 5b .	Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .
Ckp sensor rotor/cam chain drive sprocket	Refer to “engine bottom side disassembly” .	—	Refer to “engine bottom side assembly” (page 1d- 56).
Cam chain tensioner	Refer to “engine bottom side disassembly” .	Refer to “cam chain tensioner inspection” .	Refer to “engine bottom side assembly” (page 1d- 56).
Ckp sensor	Refer to “ckp sensor removal and installation” in section 1c .	Refer to “ckp sensor inspection” in section 1c .	Refer to “ckp sensor removal and installation” in section 1c .
Starter idle gear	Refer to “starter clutch removal and installation” in section 1i .	—	Refer to “starter clutch removal and installation” in section 1i .
Starter clutch	Refer to “starter clutch removal and installation” in section 1i .	Refer to “starter clutch inspection” in section 1i .	Refer to “starter clutch removal and installation” in section 1i .
Starter torque limiter	Refer to “starter torque limiter removal and installation” in section 1i .	Refer to “starter torque limiter inspection” in section 1i .	Refer to “starter torque limiter removal and installation” in section 1i .

Engine left side

Item	Removal	Inspection	Installation
Speed sensor	Refer to “speed sensor removal and installation” in section 9c .	Refer to “speed sensor inspection” in section 9c .	Refer to “speed sensor removal and installation” in section 9c .
Engine sprocket	Refer to “engine sprocket removal and installation” in section 3a .	Refer to “drive chain related parts inspection” in section 3a .	Refer to “engine sprocket removal and installation” in section 3a .
Drive chain	Refer to “drive chain replacement” in section 3a .	Refer to “drive chain inspection and adjustment” in section 0b .	Refer to “drive chain replacement” in section 3a .
Gear position switch	Refer to “gear position (gp) switch removal and installation” in section 5b .	Refer to “gear position (gp) switch inspection” in section 5b .	Refer to “gear position (gp) switch removal and installation” in section 5b .
Generator cover	Refer to “generator removal and installation” in section 1j .	—	Refer to “generator removal and installation” in section 1j .
Generator rotor	Refer to “generator removal and installation” in section 1j .	—	Refer to “generator removal and installation” in section 1j .
Water pump	Refer to “water pump removal and installation” in section 1f .	Refer to “water pump related parts inspection” in section 1f .	Refer to “water pump removal and installation” in section 1f .
Oil pressure switch	Refer to “oil pressure switch removal and installation” in section 1e .	Refer to “oil pressure indicator inspection” in section 9c .	Refer to “oil pressure switch removal and installation” in section 1e .

Repair instructions

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Air cleaner element removal and installation

Removal Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). Remove the air cleaner box cover (1). Remove the air cleaner ...

Other materials:

Gearshift shaft oil seal / bearing removal and installation
Removal Remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation” . Remove the gearshift shaft oil seal (1). Remove the bearings (2) and (3) with the special tools. Special tool (a): 09921–20210 (bearing remover (12 mm)) ...

Front brake hose routing diagram
Hose clamp : clamp end should face downward. Stopper : after the brake hose union has contacted to the stopper, tighten the union bolt. Hose guide : pass the brake hose through the hose guide. Stopper : after positioning the clamp with the stopper ...

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 ...