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:
Swingarm related parts inspection
Refer to “swingarm removal and installation” (page 2c-
9).
Spacers
Remove the collar and spacer from the swingarm.
Inspect the collars and spacer for wear and damage.
If any defects are found, replace them with new
ones.
Chain buffer
Inspect the chain buffer for wear and ...
Rear view mirror construction
Body cowling
Cowling brace
Cushion
Turn signal lead wire
Turn signal lead
wire coupler
: locate the turn signal lead wire coupler (5) between the
mirror cover (6) and mirror body (7).
Mirror cover
Mirror body
10 N·m (1.0 Kgf-m, 7.0 L ...
Spark plug inspection and cleaning
Inspect spark plug
every 6 000 km (4 000 miles, 12 months)
Heat range
Remove the spark plugs. Refer to “ignition coil and spark plug removal
and installation” in section 1h .
Check spark plug heat range by observing electrode
color. If the electrode of the spark plug is wet
appe ...