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:
Chassis bolt and nut inspection
Tighten chassis bolt and nut
initially at 1 000 km (600 miles, 2 months) and every
6 000 km (4 000 miles, 12 months) thereafter
Check that all chassis bolts and nuts are tightened to
their specified torque.
Steering stem
lock-nut 80 n·m (8.0 Kgf-m, 58.0 Lbf-ft)
Stee ...
Oil pressure indicator inspection
Inspect the oil pressure indicator in the following
procedures:
Note
before inspecting the oil pressure switch, check if the engine oil level
is correct. Refer to “engine oil and filter replacement” in section 0b .
Remove the left side cowling. Refer to “exterior parts remov ...
Battery
Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the fi system instantly when reverse
power is applied.
Removing any battery terminal of a running engine is
strictly prohibited. The moment such removal is made,
...