gsxr1000k5

PrintedinJapanK5No.7892GSX-R1000_01E99500-39270-01E2005.1.19Cover_14forPSprinting(20mm)1/199500-39270-01ETOPBOTTOMK5GSX-R1000GSX-R1000TDP7GROUPINDEXGENERALINFORMATION1PERIODICMAINTENANCE2ENGINE3FISYSTEMDIAGNOSIS4FUELSYSTEMANDTHROTTLEBODY5EXHAUSTSYSTEM6COOLINGANDLUBRICATIONSYSTEM7CHASSIS8ELECTRICALSYSTEM9SERVICINGINFORMATION10EMISSIONCONTROLINFORMATION11WIRINGDIAGRAM12FOREWORDThismanualcontainsanintroductorydescriptionontheSUZUKIGSX-R1000andproceduresforitsinspection/serviceandoverhaulofitsmaincompo-nents.Otherinformationconsideredasgenerallyknownisnotincluded.ReadtheGENERALINFORMATIONsectiontofamiliarizeyourselfwiththemotorcycleanditsmain-tenance.Usethissectionaswellasothersectionstouseasaguideforproperinspectionandservice.Thismanualwillhelpyouknowthemotorcyclebet-tersothatyoucanassureyourcustomersoffastandreliableservice.©COPYRIGHTSUZUKIMOTORCORPORATION2005*Thismanualhasbeenpreparedonthebasisofthelatestspecificationsatthetimeofpubli-cation.Ifmodificationshavebeenmadesincethen,differencesmayexistbetweenthecon-tentofthismanualandtheactualmotorcycle.*Illustrationsinthismanualareusedtoshowthebasicprinciplesofoperationandworkprocedures.Theymaynotrepresenttheactualmotorcycleexactlyindetail.*Thismanualiswrittenforpersonswhohaveenoughknowledge,skillsandtools,includingspecialtools,forservicingSUZUKImotorcy-cles.Ifyoudonothavetheproperknowledgeandtools,askyourauthorizedSUZUKImotorcycledealertohelpyou.Inexperiencedmechanicsormechanicswithoutthepropertoolsandequipmentmaynotbeabletoproperlyperformtheservicesdescribedinthismanual.Improperrepairmayresultininjurytothemechanicandmayrenderthemotorcycleunsafefortheriderandpassenger.SAMPLEHOWTOUSETHISMANUALTOLOCATEWHATYOUARELOOKINGFOR:1.Thetextofthismanualisdividedintosections.2.ThesectiontitlesarelistedintheGROUPINDEX.3.Holdingthemanualasshownattherightwillallowyoutofindthefirstpageofthesectioneasily.4.Thecontentsarelistedonthefirstpageofeachsectiontohelpyoufindtheitemandpageyouneed.COMPONENTPARTSANDWORKTOBEDONEUnderthenameofeachsystemorunit,isitsexplodedview.Workinstructionsandotherserviceinformationsuchasthetighteningtorque,lubricatingpointsandlockingagentpoints,areprovided.Example:Frontwheel1Brakedisc2Collar3Dustseal4Bearing5Spacer6Frontaxle7FrontwheelAFrontaxleboltBBrakediscboltITEMN·mkgf-mlb-ftA10010.072.5B232.316.5SAMPLESYMBOLListedinthetablebelowarethesymbolsindicatinginstructionsandotherinformationnecessaryforservic-ing.Themeaningofeachsymbolisalsoincludedinthetable.SYMBOLDEFINITIONSYMBOLDEFINITIONTorquecontrolrequired.Databesideitindicatesspecifiedtorque.ApplyTHREADLOCKSUPER“1360”.99000-32130Applyoil.Useengineoilunlessother-wisespecified.Useenginecoolant.99000-99032-11X(ExceptUSA)Applymolybdenumoilsolution.(MixtureofengineoilandSUZUKIMOLYPASTEinaratioof1:1)Useforkoil.99000-99044-L01ApplySUZUKISUPERGREASE“A”.99000-25010(Others)99000-25030(USA)Applyorusebrakefluid.ApplySUZUKIMOLYPASTE.99000-25140Measureinvoltagerange.ApplySUZUKIBOND“1215”.99000-31110(ExceptUSA)Measureincurrentrange.ApplySUZUKIBOND“1207B”.99104-31140(USA)Measureinresistancerange.ApplySUZUKIBOND“1207B”.99000-31140(ExceptUSA)Measureindiodetestrange.ApplyTHREADLOCKSUPER“1303”.99000-32030Measureincontinuitytestrange.ApplyTHREADLOCKSUPER“1322”.99000-32110(ExceptUSA)Usespecialtool.ApplyTHREADLOCK“1342”.99000-32050(USA)Indicationofservicedata.SAMPLEABBREVIATIONSUSEDINTHISMANUALAABDC:AfterBottomDeadCenterAC:AlternatingCurrentACL:AirCleaner,AirCleanerBoxAPI:AmericanPetroleumInstituteATDC:AfterTopDeadCenterATMPressure:AtmosphericPressure:AtmosphericPressuresensor(APS,APSensor)A/F:AirFuelMixtureBBBDC:BeforeBottomDeadCenterBTDC:BeforeTopDeadCenterB+:BatteryPositiveVoltageCCKPSensor:CrankshaftPositionSensor(CKPS)CKT:CircuitCLPSwitch:ClutchLeverPositionSwitch(ClutchSwitch)CMPSensor:CamshaftPositionSensor(CMPS)CO:CarbonMonoxideCPU:CentralProcessingUnitDDC:DirectCurrentDMC:DealerModeCouplerDOHC:DoubleOverHeadCamshaftDRL:DaytimeRunningLightDTC:DiagnosticTroubleCodeEECM:EngineControlModuleEngineControlUnit(ECU)(FIControlUnit)ECTSensor:EngineCoolantTemperatureSensor(ECTS),WaterTemp.Sensor(WTS)EVAP:EvaporativeEmissionEVAPCanister:EvaporativeEmissionCanister(Canister)EXCSystem:ExhaustControlSystem(EXCS)EXCValve:ExhaustControlValve(EXCV)EXCVActuator:ExhaustControlValveActuator(EXCVA)FFI:FuelInjection,FuelInjectorFP:FuelPumpFPR:FuelPressureRegulatorFPRelay:FuelPumpRelayGGEN:GeneratorGND:GroundGPSwitch:GearPositionSwitchHHC:HydrocarbonsIIAPSensor:IntakeAirPressureSensor(IAPS)(MAPSensor)IATSensor:IntakeAirTemperatureSensor(IATS)IG:IgnitionLLCD:LiquidCrystalDisplayLED:LightEmittingDiode(MalfunctionIndicatorLamp)LH:LeftHandSAMPLEMMAL-Code:MalfunctionCode(DiagnosticCode)Max:MaximumMIL:MalfunctionIndicatorLamp(LED)Min:MinimumNNOX:NitrogenOxidesOOHC:OverHeadCamshaftOPS:OilPressureSwitchPPCV:PositiveCrankcaseVentilation(CrankcaseBreather)RRH:RightHandROM:ReadOnlyMemorySSAE:SocietyofAutomotiveEngineersSDS:SuzukiDiagnosisSystemSTCSystem:SecondaryThrottleControlSystem(STCS)STPSensor:SecondaryThrottlePositionSensor(STPS)STValve:Second