Suzuki GSX-R 1000 Service Manual: General precautions

Suzuki GSX-R 1000 Service Manual / Precautions / General precautions

Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.
When 2 or more persons work together, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material manufacturer’s instructions.
Never use gasoline as cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled.
After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks.

Caution

If parts replacement is necessary, replace the parts with suzuki genuine parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean. Lubricate them when specified.
Use the specified lubricant, bond or sealant.
When removing the battery, disconnect the negative (–) cable first and then the positive (+) cable.
When reconnecting the battery, connect the positive (+) cable first and then the negative (–) cable, and replace the terminal cover on the positive (+) terminal.
When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative (–) cable the battery.
When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, o-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
After reassembling, check parts for tightness and proper operation.
To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires.
To protect earth’s natural resources, properly dispose of used motorcycle and parts.

Warning / caution / note

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to t ...

Precautions for electrical circuit service

When handling the electrical parts or servicing fi system, observe the following points for the safety of the systems. ...

Other materials:

Specifications
Service data Wheel unit: mm (in) Tire Tightening torque specifications Note the specified tightening torque is described in the following. “Front wheel components” “front wheel assembly construction” “rear wheel components” “rear wheel assembly c ...

Combination meter inspection
Led inspection Check that the leds “a” (fi, fuel, engine rpm, oil pressure/engine coolant, immobilizer (e-02, 19, 24, 51) and meter panel illumination) immediately light up when the ignition switch is turned on. Check that the other leds “b” (neutral, high-beam and turn signal indicator ligh ...

Front fork components
Front fork cap O-ring Rebound damping force adjuster rod Compression damping force adjuster rod Piston rod nut O-ring Piston ring Rod guide case Spring Piston rod Spring collar b Spring Spring collar a Slide bushing Outer tu ...