Suzuki GSX-R 1000 Service Manual: Muffler / muffler chamber / exhaust pipe removal and installation
Removal
- Loosen the muffler connecting bolts (1).
- Remove the mufflers (2) by removing the mounting bolt and nut (3).
| Note support the muffler to prevent it from falling. |
- Remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
- Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
- Disconnect the ho2 sensor coupler (4).
- Remove the muffler chamber heat guard no. 2 (5).
(Rh only)
- Loosen the muffler chamber connecting bolt (6).
- Remove the muffler chamber (7).
- Remove the muffler chamber heat guard no. 1 (8) And ho2 sensor (9) from the muffler chamber.
Caution
|
- Remove the excv cables (10). Refer to “excv cable removal and installation” .
- Move the radiator and oil cooler forward. Refer to “radiator inspection and cleaning” in section 1f .
- Remove the exhaust pipe assembly by removing the exhaust pipe bolts.
| Caution take care not to bend the radiator/oil cooler fins. |
| Note support the exhaust pipe assembly to prevent it from falling. |
- Remove the exhaust pipe gaskets (11).
Installation
Installation is in the reverse order of removal. Pay attention to the following points:
- tighten the ho2 sensor to the specified torque.
Tightening torque ho2 sensor (a): 25 n·m (2.5 Kgf-m, 18.0 Lbf-ft)
Caution
|
- Install new gaskets and connectors and tighten each bolt to the specified torque. Refer to “exhaust system components” .
| Caution replace the gaskets and connectors with new ones. |
| Note when installing a new connector, remove all of the old sealer. Apply the exhaust gas sealer to both the inside and outside of the new connector. |
: Muffler seal (muffler
seal loctite
5920 (commercially available) or equivalent)
- Install the excva cables. Refer to “excv cable removal and installation” .
Excva adjustment
Inspect the excva operation and adjust it if necessary
in the following steps:
Step 1
Set the excva to the adjustment position. Refer to
“excv cable removal and installation” (page 1k-
6).
...
Exhaust system inspection
Inspect the exhaust pipe, muffler chamber and muffler
connection for exhaust gas leakage and mounting
condition. If any defect is found, replace the exhaust
pipe, muffler chamber or muffler with a ...
Other materials:
Gear position (gp) switch removal and installation
Removal
Turn the ignition switch off.
Lift and support the fuel tank. Refer to “fuel tank
removal and installation” in section 1g (page 1g-
9).
Disconnect the gear position switch lead wire
coupler (1).
Remove the engine sprocket cover. Refer to “engine sprocket r ...
Specifications
Service data
Wattage
unit: w
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Rear lighting system construction” “license plate light
components” “reflex reflector construction”
Reference: for the ...
Rear lighting system construction
License plate light assembly
Reflex reflector (e-03, 28, 33 only)
Clamp
: clamp the license plate light lead wire
so as not to be slack.
Rear combination light
Rear turn signal light assembly (lh/rh)
5
N·m (0.5 Kgf-m, 3.5 Lbf-ft)
1.8 N·m
...