Suzuki GSX-R1000 - User Manual

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No. 1298 GSX-R1000 S/M 99500-39380-01E For PS printing 2009.3.3 (Back: 23 mm) 5/0

DIC255

GSX-R1000

Printed in Japan

GSX-R1000

SERVICE MANUAL

9 9 5 0 0 - 3 9 3 8 0 - 0 1 E

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys

email: info@motomatrix.co.uk / www.motomatrix.co.uk

Main Page

Default Chapter3
- Table of Contents3
- Precautions5
- General Precautions6
- Electrical Parts7
- Precautions for Electrical Circuit Service7
- Connector / Coupler7
- Clamp8
- ECM / Various Sensors8
- Fuse8
- Switch8
- Open Circuit Check9
- Battery9
- Electrical Circuit Inspection Procedure9
- Continuity Check10
- Voltage Check10
- Short Circuit Check (Wire Harness to Ground)11
- Using the Multi-Circuit Testers12
- Using the Testers12
- General Information13
- Symbols14
- General Description14
- Abbreviations14
- Vehicle Side View15
- Brake Fluid16
- Engine Oil (for USA)16
- Fuel and Oil Recommendation16
- Vehicle Identification Number16
- BREAK-IN Procedures17
- Cylinder Identification17
- Engine Coolant Recommendation17
- Wire Color Symbols18
- Country and Area Codes18
- Warning, Caution and Information Labels Location19
- Component Location20
- Electrical Components Location20
- Specifications22
- Special Tools and Equipment24
- Maintenance and Lubrication28
- Recommended Fluids and Lubricants28
- Periodic Maintenance Schedule Chart29
- Scheduled Maintenance29
- Repair Instructions30
- Air Cleaner Element Inspection30
- Lubrication Points30
- Air Cleaner Element Replacement30
- Exhaust Control Valve Inspection31
- Exhaust Pipe Bolt and Muffler Bolt Inspection31
- Valve Clearance Inspection and Adjustment32
- Electrodes Condition36
- Spark Plug Inspection and Cleaning36
- Spark Plug Replacement36
- Fuel Line Inspection37
- Engine Oil Replacement37
- Evaporative Emission Control System Inspection (E-33 Only)37
- Engine Oil and Filter Replacement37
- Oil Filter Replacement38
- Oil Level Inspection38
- Cooling System Inspection39
- PAIR System Inspection39
- Throttle Cable Play Inspection and Adjustment39
- Throttle Valve Synchronization39
- Radiator Hose Inspection40
- Engine Coolant Change40
- Air Bleeding from the Cooling Circuit40
- Clutch Cable Play Inspection and Adjustment41
- Drive Chain Inspection and Adjustment41
- Drive Chain Length Inspection42
- Drive Chain Slack Adjustment42
- Brake Fluid Level Check43
- Brake System Inspection43
- Drive Chain Cleaning and Lubricating43
- Front and Rear Brake Hose Inspection44
- Brake Pads Check44
- Brake Pedal Height Inspection and Adjustment44
- Brake Hose Replacement44
- Inspect Steering System45
- Steering System Inspection45
- Tire Inspection45
- Tire Pressure45
- Chassis Bolt and Nut Inspection46
- Front Fork Inspection46
- Rear Suspension Inspection46
- Tighten Chassis Bolt and Nut46
- Tightening Torque Specifications48
- Compression Pressure Check48
- Recommended Service Material49
- Special Tool49
- Service Data50
- Tightening Torque List58
- Table of Contents63
- Engine63
Precautions68
- Precautions for Engine68
Engine General Information and Diagnosis69
- Injection Timing Description69
- Self-Diagnosis Function71
- User Mode71
- Schematic and Routing Diagram72
- Component Location75
- Diagnostic Information and Procedures76
Specifications206
- Service Data206
Special Tools and Equipment207
- Special Tool207
Emission Control Devices209
- Fuel Injection System Description209
- Precautions209
  - Precautions for Emission Control Devices209
- General Description209
- Schematic and Routing Diagram214
- Repair Instructions216
- Specifications224
  - Service Data224
  - Tightening Torque Specifications224
- Special Tools and Equipment224
- Precautions225
  - Precautions for Engine Electrical Device225
- Component Location225
  - Engine Electrical Components Location225
- Diagnostic Information and Procedures225
  - Engine Symptom Diagnosis225
- Repair Instructions225
- Specifications233
  - Service Data233
  - Tightening Torque Specifications233
- Special Tools and Equipment234
  - Special Tool234
Engine Mechanical235
- Camshaft and Sprocket Assembly Diagram235
- Schematic and Routing Diagram235
  - Throttle Cable Routing Diagram236
  - Engine Mechanical Symptom Diagnosis237
- Diagnostic Information and Procedures237
  - Compression Pressure Check237
  - Engine Components Removable with the Engine in Place238
- Repair Instructions238
- Specifications318
  - Service Data318
  - Tightening Torque Specifications320
- Special Tools and Equipment321
  - Recommended Service Material321
  - Special Tool322
Engine Lubrication System325
- Precautions325
  - Precautions for Engine Oil325
  - Engine Lubrication System Chart Diagram326
- Schematic and Routing Diagram326
- Diagnostic Information and Procedures329
  - Engine Oil Level Inspection330
  - Oil Pan / Oil Pressure Regulator / Oil Strainer Removal and Installation330
- Repair Instructions330
- Specifications338
  - Service Data338
  - Tightening Torque Specifications338
- Special Tools and Equipment339
  - Recommended Service Material339
  - Special Tool339
Engine Cooling System340
- Precautions for Engine Cooling System340
- Engine Coolant Description340
- Anti-Freeze Proportioning Chart340
- General Description340
  - Cooling Circuit Diagram341
- Schematic and Routing Diagram341
- Diagnostic Information and Procedures343
- Repair Instructions343
- Specifications357
  - Service Data357
  - Tightening Torque Specifications358
- Special Tools and Equipment358
  - Recommended Service Material358
  - Special Tool358
Fuel System359
- Precautions359
  - Precautions for Fuel System359
- General Description360
  - Fuel Injection System Description360
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram361
- Schematic and Routing Diagram361
  - Fuel System Diagnosis362
- Diagnostic Information and Procedures362
  - Fuel Pressure Inspection363
- Repair Instructions363
- Specifications372
  - Service Data372
  - Tightening Torque Specifications372
- Special Tools and Equipment373
  - Recommended Service Material373
  - Special Tool373
Ignition System374
- Immobilizer Description (for E-02, 19, 24, 51)374
- General Description374
- Schematic and Routing Diagram376
  - Ignition System Components Location376
  - Ignition System Symptom Diagnosis377
- Diagnostic Information and Procedures377
  - No Spark or Poor Spark378
  - Ignition Coil and Spark Plug Removal and Installation379
- Repair Instructions379
- Specifications386
  - Service Data386
  - Tightening Torque Specifications386
- Special Tools and Equipment387
- Schematic and Routing Diagram388
  - Starting System Diagram388
- Component Location388
  - Starting System Components Location388
- Diagnostic Information and Procedures388
- Repair Instructions390
- Specifications399
  - Service Data399
  - Tightening Torque Specifications399
- Special Tools and Equipment400
- Schematic and Routing Diagram401
- Component Location401
  - Charging System Components Location401
- Diagnostic Information and Procedures401
- Repair Instructions403
- Specifications412
  - Service Data412
  - Tightening Torque Specifications412
- Special Tools and Equipment413
  - Recommended Service Material413
  - Special Tool413
Exhaust System414
- Precautions for Exhaust System414
- Exhaust Control System Description414
- General Description414
  - Exhaust Control System Operation415
- Repair Instructions417
Specifications427
- Service Data427
- Tightening Torque Specifications427
Special Tools and Equipment428
- Recommended Service Material428
- Suspension429
Precautions430
- Precautions for Suspension430
- Suspension General Diagnosis431
- Suspension and Wheel Symptom Diagnosis431
- Diagnostic Information and Procedures431
- Front Suspension432
- Front Fork Components432
- Repair Instructions432
- Front Fork Removal and Installation433
- Front Suspension Adjustment435
- Front Fork Disassembly and Assembly435
  - Spring Pre-Load Adjustment435
  - Damping Force Adjustment435
- Front Fork Parts Inspection441
  - Slide Bushing / Guide Bushing441
  - Fork Spring441
- Rod Guide Case Tightening Torque441
- Specifications442
- Service Data442
- Tightening Torque Specifications442
- Special Tools and Equipment443
- Recommended Service Material443
- Special Tool443
- Rear Suspension Components444
- Repair Instructions444
- Rear Suspension Assembly Construction445
- Rear Shock Absorber Removal and Installation446
- Rear Suspension Inspection446
- Rear Shock Absorber Bearing Removal and Installation447
- Rear Shock Absorber Adjustment448
  - Rebound Side448
  - STD Position448
  - Compression Side (Low Speed)449
  - Compression Side (High Speed)449
  - Gas Pressure Release449
- Rear Shock Absorber Disposal449
- Cushion Lever Removal and Installation450
- Cushion Rod Removal and Installation450
- Cushion Lever Inspection450
  - Collar and Spacer451
  - Cushion Rod Bearing451
- Cushion Rod Inspection451
- Cushion Rod Bearing Removal and Installation452
- Swingarm Removal and Installation452
- Special Tool454
- Swingarm Pivot Boss Removal and Installation455
- Swingarm Related Parts Inspection455
- Swingarm Bearing Removal and Installation456
  - Plate456
  - Swingarm Pivot Shaft456
- Specifications458
- Service Data458
- Tightening Torque Specifications458
- Special Tools and Equipment459
- Recommended Service Material459
- Special Tool459
- Wheels and Tires460
- Precautions for Wheel and Tire460
- Front Wheel Components461
- Repair Instructions461
- Front Wheel Assembly Construction462
- Front Wheel Assembly Removal and Installation463
  - Dust Seal465
  - Wheel Axle465
  - Wheel Axle Runout465
- Front Wheel Related Parts Inspection465
- Front Wheel Dust Seal / Bearing Removal and Installation466
- Rear Wheel Components468
- Rear Wheel Assembly Construction469
- Rear Wheel Assembly Removal and Installation470
- Rear Wheel Related Parts Inspection471
- Rear Wheel Dust Seal / Bearing Removal and Installation472
- Tire Removal and Installation473
- Wheel / Tire / Air Valve Inspection and Cleaning475
- Air Valve Removal and Installation475
- Wheel Balance Check and Adjustment476
- Specifications477
- Service Data477
- Tightening Torque Specifications477
- Special Tools and Equipment478
- Recommended Service Material478
- Special Tool478
- Driveline / Axle479
Precautions480
- Precautions for Driveline / Axle480
- Drive Chain / Drive Train / Drive Shaft481
- Drive Chain and Sprocket Symptom Diagnosis481
- Drive Chain Related Components481
- Diagnostic Information and Procedures481
- Repair Instructions481
- Engine Sprocket Removal and Installation482
- Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation483
- Drive Chain Related Parts Inspection485
- Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation485
  - Engine Sprocket and Rear Sprocket485
  - Wheel Damper485
- Drive Chain Replacement487
- Specifications490
- Service Data490
- Tightening Torque Specifications490
- Special Tools and Equipment491
- Recommended Service Material491
- Special Tool491
- Brake493
Precautions494
- Brake Fluid Information494
- Precautions for Brake System494
- Brake Control System and Diagnosis495
- Front Brake Hose Routing Diagram495
- Schematic and Routing Diagram495
- Rear Brake Hose Routing Diagram496
- Brake Symptom Diagnosis497
- Front Brake Light Switch Inspection497
- Diagnostic Information and Procedures497
- Repair Instructions497
- Brake Pedal Height Inspection and Adjustment497
- Rear Brake Light Switch Inspection and Adjustment498
- Air Bleeding from Brake Fluid Circuit498
- Brake Fluid Level Check498
- Brake Hose Inspection498
- Front Brake499
- Brake Fluid Replacement500
- Rear Brake501
- Front Brake Hose Removal and Installation502
- Front Brake Master Cylinder Components503
- Front Brake Master Cylinder Assembly Removal and Installation504
- Front Brake Master Cylinder / Brake Lever Disassembly and Assembly505
- Piston / Rubber Parts507
- Front Brake Master Cylinder Parts Inspection507
- Rear Brake Master Cylinder Components508
- Rear Brake Master Cylinder Assembly Removal and Installation509
- Rear Brake Master Cylinder Disassembly and Assembly510
- Rear Brake Master Cylinder Parts Inspection511
- Rear Brake Pedal Construction512
- Rear Brake Pedal Removal and Installation512
- Specifications513
- Service Data513
- Tightening Torque Specifications513
- Special Tools and Equipment514
- Recommended Service Material514
- Special Tool514
- Front Brake Components515
- Repair Instructions515
- Front Brake Pad Inspection516
- Front Brake Pad Replacement516
- Front Brake Caliper Removal and Installation517
- Front Brake Caliper Disassembly and Assembly517
  - Brake Caliper Cylinder519
  - Brake Caliper Piston519
  - Brake Pad Mounting Pin519
  - Brake Pad Spring519
- Front Brake Caliper Parts Inspection519
- Front Brake Disc Removal and Installation520
- Front Brake Disc Inspection520
  - Brake Disc Thickness520
  - Brake Disc Runout520
- Specifications521
- Service Data521
- Tightening Torque Specifications521
- Special Tools and Equipment522
- Recommended Service Material522
- Special Tool522
- Rear Brake Components523
- Repair Instructions523
- Rear Brake Pad Inspection524
- Rear Brake Pad Replacement524
- Rear Brake Caliper Removal and Installation525
- Rear Brake Caliper Disassembly and Assembly526
  - Brake Caliper Sliding Pin528
  - Boot528
- Rear Brake Disc Removal and Installation528
- Rear Brake Caliper Parts Inspection528
- Rear Brake Disc Inspection529
- Specifications529
- Service Data529
- Tightening Torque Specifications530
- Special Tools and Equipment530
- Recommended Service Material530
- Special Tool530
- Transmission / Transaxle531
Precautions532
- Precautions for Transmission / Transaxle532
- Manual Transmission Symptom Diagnosis533
- Diagnostic Information and Procedures533
- Transmission Components534
- Repair Instructions534
- Transmission Removal535
  - Countershaft Assembly535
  - Gearshift Fork and Gearshift Cam535
  - Driveshaft Assembly535
  - Bearing and Oil Seal536
- Transmission Installation537
- Transmission Construction541
- Countershaft Gear / Driveshaft Gear Disassembly and Assembly542
  - Driveshaft543
  - Countershaft543
- Transmission Related Parts Inspection544
  - Gearshift Fork to Groove Clearance544
  - Gearshift Fork Groove Width544
  - Gearshift Fork Thickness544
  - Gearshift Cam545
  - Gearshift Cam Bearing545
  - Driveshaft Bearing545
  - Driveshaft Oil Seal545
- Gear Position (GP) Switch Inspection545
- Gear Position (GP) Switch Removal and Installation546
- Gearshift Lever Construction547
- Gearshift Lever Removal and Installation547
- Gearshift Lever Height Inspection and Adjustment548
- Gearshift Shaft / Gearshift Cam Plate Components548
- Gearshift Shaft Construction549
- Gearshift Shaft / Gearshift Cam Plate Removal and Installation549
- Gearshift Shaft Bearing552
- Gearshift Shaft Oil Seal / Bearing Removal and Installation552
- Gearshift Linkage Inspection552
- Specifications553
- Service Data553
- Tightening Torque Specifications554
- Special Tools and Equipment554
- Recommended Service Material554
- Special Tool555
- Clutch System Symptom Diagnosis556
- Precautions556
- Precautions for Clutch System556
- Schematic and Routing Diagram556
- Clutch Cable Routing Diagram556
- Diagnostic Information and Procedures556
- Clutch Lever Position Switch Inspection557
- Clutch Cable Removal and Installation557
- Repair Instructions557
- Clutch Control System Components558
- Clutch Components559
- Clutch Removal560
- Clutch Installation562
  - Clutch Drive and Driven Plate566
  - Clutch Drive Plate Claw Width566
  - Clutch Driven Plate Distortion566
  - Clutch Spring566
- Clutch Parts Inspection566
  - Clutch Release Bearing567
  - Push Rod (Right)567
  - Clutch Sleeve Hub and Primary Driven Gear Assembly567
  - Wave Spring Washer567
- Clutch Lifter Pin Inspection and Adjustment568
- Specifications569
- Service Data569
- Tightening Torque Specifications569
- Special Tools and Equipment570
- Recommended Service Material570
- Special Tool570
- Steering571
Precautions572
- Precautions for Steering572
- Steering General Diagnosis573
- Steering Symptom Diagnosis573
- Diagnostic Information and Procedures573
- Steering / Handlebar574
- Handlebar Components574
- Repair Instructions574
- Handlebar Removal and Installation575
- Handlebars Inspection577
- Steering Components578
- Steering Damper Construction579
- Steering / Steering Damper Removal and Installation579
- Steering Stem Nut581
- Steering / Steering Damper Related Parts Inspection582
  - Steering Stem Upper Bracket582
  - Steering Damper582
- Steering Stem Bearing Removal and Installation583
- Steering System Inspection583
- Steering Tension Adjustment584
  - Outer Race584
  - Inner Race584
- Specifications585
- Tightening Torque Specifications585
- Special Tools and Equipment586
- Recommended Service Material586
- Special Tool586
- Body and Accessories587
Precautions589
- Precautions for Electrical System589
- Component Location589
- Electrical Components Location589
- Wiring Systems590
- Schematic and Routing Diagram590
- Wiring Diagram590
- Wiring Harness Routing Diagram596
- Specifications600
- Service Data600
- Tightening Torque Specifications600
- Special Tools and Equipment600
- Recommended Service Material600
- Lighting Systems601
- Headlight Components601
- Headlight Removal and Installation601
- Repair Instructions601
- Headlight Bulb and Position Light Bulb Replacement602
  - Low Beam Bulb602
  - High Beam Bulb602
- Headlight Beam Adjustment603
- Position Light Bulb603
- Front Turn Signal Light Components603
- Front Turn Signal Light Removal and Installation604
- Front Turn Signal Light Bulb Replacement604
- Rear Lighting System Construction605
- Rear Combination Light Removal and Installation606
- Rear Combination Light Replacement606
- License Plate Light Components607
- License Plate Light Removal and Installation607
- License Plate Light Bulb Replacement608
- Rear Turn Signal Light Components609
- Rear Turn Signal Light Removal and Installation609
- Rear Turn Signal Light Bulb Replacement610
- Reflex Reflector Construction610
- Turn Signal / Side-Stand Relay Inspection611
- Hazard Switch Inspection611
- Turn Signal / Side-Stand Relay Removal and Installation611
- Turn Signal Switch Inspection612
- Dimmer / Passing Light Switch Inspection612
- Specifications613
- Service Data613
- Tightening Torque Specifications613
- Special Tools and Equipment613
- Recommended Service Material613
- Special Tool613
- Combination Meter / Fuel Meter / Horn614
- Combination Meter System Description614
  - LED (Light Emitting Diode)614
  - Engine RPM Indicator Light614
- General Description614
- Combination Meter Components615
- Combination Meter Removal and Installation615
- Repair Instructions615
- Combination Meter Disassembly and Assembly616
- Combination Meter Inspection616
- Stepping Motor Inspection and Adjustment616
- Engine Coolant Temperature Indicator Light Inspection617
- ECT Sensor Removal and Installation617
- Fuel Level Indicator Inspection618
- Fuel Level Gauge Inspection618
- Speedometer Inspection618
- Speed Sensor Removal and Installation618
- Speed Sensor Inspection619
- Oil Pressure Indicator Inspection619
- Oil Pressure Switch Inspection620
- Ignition Switch Inspection620
- Oil Pressure Switch Removal and Installation620
- Ignition Switch Removal and Installation620
- Horn Inspection621
- Horn Removal and Installation621
- Specifications622
- Service Data622
- Tightening Torque Specifications622
- Special Tools and Equipment622
- Exterior Parts Construction623
- Repair Instructions623
- Rear Fender Construction624
- Frame Cover Construction625
- Rear View Mirror Construction626
- Fastener Removal and Installation627
- Exterior Parts Removal and Installation628
  - Side Frame Cover628
  - Rear Seat / Seat Tail Cover628
  - Windscreen629
  - Body Cowling Cover630
  - Side Cowling630
  - Inner under Cowling631
  - Body Cowling631
  - Intake Pipe632
  - Cowling Brace632
  - Frame Cover633
- Specifications634
- Tightening Torque Specifications634
- Body Structure635
- Body Frame Construction635
- Repair Instructions635
- Front Footrest Bracket Construction636
- Side-Stand Construction637
- Pillion Footrest Construction638
- Side-Stand Removal and Installation638
- Specifications639
- Tightening Torque Specifications639
- Special Tools and Equipment639
- Recommended Service Material639

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Suzuki GSX-R1000 Specifications

General

Front Suspension	Inverted telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Fuel Tank Capacity	16.0 L (4.2 US gal)
Overall Length	2, 075 mm (81.7 in)
Wheelbase	1, 420 mm (55.9 in)
Ground Clearance	130 mm (5.1 in)
Seat Height	825 mm (32.5 in)
Starter	Electric
Final Drive	Chain
Front Brakes Brand	Brembo
Displacement	999.8cc
Bore x Stroke	55.1mm
Fuel System	Fuel injection
Transmission	6-speed constant mesh
Front Tire	120/70ZR17M/C (58W)
Engine Type	4-stroke, liquid-cooled, DOHC, 4-cylinder