Suzuki GSX-R 1000 Service Manual: 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.
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 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.
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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 ...
When handling the electrical parts or servicing fi
system, observe the following points for the safety of the
systems. ...
Other materials:
Exhaust system components
Exhaust pipe gasket
Exhaust pipe assembly
Ho2 sensor
Connector
: install the connector so that the
chamfer side faces backward.
Muffler chamber
Muffler body
Excv cable no. 1
Excv cable no. 2
When loosening or tightening the pulley bol ...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Starter motor components”
Special tool
...
Excva pulley inspection
Inspect the excva pulley in the following procedures:
remove the excva pulley. Refer to “excv cable removal and installation”
.
Visually inspect the excva pulley for wear and
damage. If there is anything unusual, replace the
pulley with a new one.
Install the pulle ...
Warning / caution / note
Precautions for electrical circuit service