Suzuki GSX-R 1000 Service Manual: Fuel pump disassembly and assembly
Disassembly
- Remove the fuel tank. Refer to “fuel tank removal and installation” .
- Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.
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- Disconnect the lead wires (2).
- Remove the fuel level gauge (3).
- Remove the fuel pressure regulator assembly (4).
| Caution never remove the fuel pressure regulator (5) from the holder. |
- Remove the o-ring (6) and fuel pump case (7).
- Remove the o-ring (8) and joint (9).
- Remove the o-ring (10) and lead wires (11).
- Remove the fuel mesh filter (12).
- Remove the fuel pump (13).
Assembly
Refer to “fuel mesh filter inspection and cleaning” .
Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points:
Caution
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| Caution connect all lead wires securely so as not to cause contact failure. |
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- Install a new o-ring and apply grease to it.
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
 The o-ring
must be replaced with a new one to prevent fuel leakage. |
- When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending of numbers.
Tightening torque fuel pump mounting bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)
Fuel pump components
Fuel level gauge
Fuel pressure regulator assembly
O-ring
Joint
Fuel pump
Fuel pump case
Fuel mesh filter
10
N·m (1.0 Kgf-m, 7.0 Lbf-ft)
Appl ...
Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:
remove the fuel mesh filter. Refer to “fuel pump disassembly and
assembly” .
If the fuel mesh filter is clogged with fore ...
Other materials:
Rear brake caliper parts inspection
Refer to “rear brake caliper disassembly and assembly” .
Brake caliper cylinder
Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any damage is found,
replace the caliper with a new one.
Brake caliper piston
Inspect the brake caliper piston surface for any
s ...
Countershaft gear / driveshaft gear
disassembly and assembly
Refer to “transmission removal” and “transmission installation” .
Disassembly
Caution
identify the position of each removed part.
Organize the parts in their respective groups
(i.E., Drive or driven) so that they can be
reinstalled in their original positions.
Counte ...
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 ...