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Suzuki GSX-R 1000 Service Manual: Ignition coil and spark plug removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Ignition system / Repair instructions / Ignition coil and spark plug removal and installation

Removal

The hot
engine can burn you.

Wait until the engine is cool enough to touch.

  1. Turn the ignition switch off.
  2.  Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .
  3.  Disconnect the lead wire couplers (1).

Suzuki GSX-R. Ignition coil and spark plug removal and installation


Caution

disconnect the lead wire coupler before removing the ignition coil to avoid lead wire coupler damage.

  1. Remove the ignition coils (2).
Caution

  •  do not pry up the ignition coil with a screwdriver or a bar to avoid its damage.
  •  Be careful not to drop the ignition coil to prevent short/open circuit.

Suzuki GSX-R. Ignition coil and spark plug removal and installation


  1. Remove the spark plugs with the spark plug wrench.

Special tool (a): 09930–10121 (spark plug wrench
set)

Suzuki GSX-R. Ignition coil and spark plug removal and installation


Installation

Install the spark plugs in the reverse order of removal.

Pay attention to the following points:

Caution

do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

Special tool (a): 09930–10121 (spark plug wrench
set)

Tightening torque spark plug: 11 n·m (1.1 Kgf-m, 8.0 Lbf-ft)

Suzuki GSX-R. Ignition coil and spark plug removal and installation


Caution

do not hit the ignition coil with a plastic hammer when installing it.

Suzuki GSX-R. Ignition coil and spark plug removal and installation


Suzuki GSX-R. Ignition coil and spark plug removal and installation


Spark plug inspection and cleaning

Refer to “spark plug inspection and cleaning” in section 0b .

Repair instructions
...

Ignition coil inspection
Refer to “electrical components location” in section 0a . Ignition coil primary peak voltage Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d . D ...

Other materials:

Cooling fan relay inspection
Inspect the fan relay in the following procedures:  remove the frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Remove the cooling fan relay (1). First check the insulation between “a” and “b” terminals with tester. Then ap ...

Gearshift shaft oil seal / bearing removal and installation
Removal Remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation” .  Remove the gearshift shaft oil seal (1). Remove the bearings (2) and (3) with the special tools. Special tool (a): 09921–20210 (bearing remover (12 mm)) ...

Engine bottom side assembly
Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: Note apply engine oil to each running and sliding part before reassembling. Breather oil return plate When installing the breather oil return plate (1), apply thread loc ...

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