Suzuki GSX-R 1000 Service Manual: Fuel pump disassembly and assembly

Disassembly

1. Remove the fuel tank. Refer to “fuel tank removal and installation” .
2.  Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.

3. Disconnect the lead wires (2).

4. Remove the fuel level gauge (3).

5. Remove the fuel pressure regulator assembly (4).

6. Remove the o-ring (6) and fuel pump case (7).

7. Remove the o-ring (8) and joint (9).
8. Remove the o-ring (10) and lead wires (11).

9. Remove the fuel mesh filter (12).
10.  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:

• 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)