Suzuki GSX-R1000 Manuale utente

FOREWORD GROUP INDEX

COOLING

AND

LUBRICATION

SYSTEM

FUEL SYSTEM

AND

THROTTLE

BODY

EMISSION CONTROL

INFORMATION

~----.

===================

___

~-_.

IPERIODIC MAINTENANCE

IGENERAL INFORMATlON

IFI SYSTEM DIAGNOSIS

IENGINE

IEXHAUSTSYSTEM

ICHASSIS

IELECTRICAL SYSTEM

IWIRING DIAGRAM

ISERVICING INFORMATlON

*This manual has been prepared on the basis

the latest specifications at the time of publi-

cation.

modifications have been made since

then, differences

may

exist between the con-

tent

this manual and the actualmotorcycle.

*Illustrations in this manual are used to show

the basic principles

operation

and

work

procedures. They may not represent the

actual motorcycle exactly in detail.

*This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles.

you do not have the properknowledge

and

tools, ask

your

authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

AWARNING

This manual contains an introductory description on

the SUZUKI GSX-R1000 and procedures for its

inspection/service

and

overhaul

its main compo-

nents.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourselfwith the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers

fast

and reliable service.

SUZUKI MOTOR CORPORATION

©COPYRIGHT SUZUKI MOTOR CORPORATION 2003

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

\,---

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

Brake disc

Dust seal

@Bearing

@Spacer

@Spacer nut

@Front wheel

®Front axle

®Brake disc bolt (Front)

r!J

ITEM N·m kgf-m

Ib-ft

®100 10.0 72.5

®23 2.3 16.5

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required. •Apply THREAD LOCK SUPER "1360".

Data beside it indicates specified 99000-32130

torque.

l!r

Apply oil. Use engine oil unless other- eUse engine coolant.

wise specified.

lIr Apply molybdenum oil solution. eUse fork oil.

(Mixture of engine oil and SUZUKI 99000-99044-LO1

MOLY

PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE "A". I

99000-25010 (Others) Apply or use brake fluid.

99000-25030 (USA)

Apply SUZUKI

MOLY

PASTE.

Measure in voltage range.

99000-25140

€i]J

Apply SUZUKI BOND "1215".

Measure in current range.

99000-31110 (Except USA)

-41207~

Apply SUZUKI BOND "1207B".

Measure in resistance range.

99104-31140 (USA)

-41207~

Apply SUZUKI BOND "1207B".

Measure in diode test range.

99000-31140 (Except USA)

Apply THREAD

LOCK

SUPER "1303".

Measure in continuity test range.

99000-32030

•Apply THREAD LOCK SUPER "1322".

l+ooLI

Use special tool.

99000-32110 (Except USA)

•Apply THREAD LOCK "1342". -Indication of service data.

99000-32050 (USA)

ABBREVIATIONS USED IN THIS

MANUAL

AABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure: Atmospheric Pressure

:Atmospheric Pressure sensor

(APS, AP Sensor)

A/F : Air Fuel Mixture

EECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

EVAP : Evaporative Emission

EVAP Canister: Evaporative Emission

Canister (Canister)

EXC System : Exhaust Control System (EXCS)

EXC Valve : Exhaust Control Valve (EXCV)

EXCV Actuator: Exhaust Control Valve Actuator

(EXCVA)

BBBDC

BTDC

B+

CCKP Sensor

CKT

CLP Switch

CMP Sensor

CPU

DDC

DMC

DOHC

DRL

: Before Bottom Dead Center

: Before Top Dead Center

: Battery Positive Voltage

:Crankshaft Position Sensor

(CKPS)

:Circuit

: Clutch Lever Position Switch

(Clutch Switch)

:Camshaft Position Sensor

(CMPS)

: Carbon Monoxide

: Central Processing Unit

: Direct Current

: Dealer Mode Coupler

: Double Over Head Camshaft

: Daytime Running Light

FFI

FPR

FP Relay

GGEN

GND

GP Switch

HHC

IlAP Sensor

IAT Sensor

LLCD

LED

: Fuel Injection, Fuel Injector

: Fuel Pump

: Fuel Pressure Regulator

: Fuel Pump Relay

:Generator

: Ground

:Gear Position Switch

:Hydrocarbons

: Intake Air Pressure Sensor (lAPS)

: Intake Air Temperature Sensor

(lATS)

: Ignition

: Liquid Crystal Display

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand

MAL-Code

Max

MIL

Min

NNOX

oOHC

OPS

pPCV

RRH

ROM

SSAE

STC System

STP Sensor

ST Valve

STV Actuator

TTO Sensor

TP Sensor

TPC Valve

:Malfunction Code

(Diagnostic Code)

:Maximum

:Malfunction Indicator Lamp

(LED)

: Minimum

:Nitrogen Oxides

: Over Head Camshaft

: Oil Pressure Switch

: Positive Crankcase

Ventilation (Crankcase Breather)

: Right Hand

: Read Only Memory

:Society of Automotive Engineers

:Secondary Throttle Control System

(STCS)

:Secondary Throttle Position Sensor

(STPS)

:Secondary Throttle Valve (STV)

:Secondary Throttle Valve Actuator

(STVA)

: Tip Over Sensor (TOS)

:Throttle Position Sensor (TPS)

: Tank Pressure Control Valve (TPCV)

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM

FORMER

SUZUKI

TERM

FULL TERM ABBREVIATION

Air Cleaner

ACl

Air Cleaner, Air Cleaner Box

Barometric Pressure BARO Barometric Pressure, Atmospheric

Pressure (APS, AP Sensor)

Battery Positive Voltage B+ Battery Voltage, +B

Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

Data Link Connector

DlC

Dealer Mode Coupler

Diagnostic Test Mode DTM -

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

Electronic Ignition EI -

Engine Control Module ECM Engine Control Module (ECM)

FI Control Unit, Engine Control Unit (ECU)

Engine Coolant

level

ECl

Coolant

level

Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-

perature

Water Temperature

Engine Speed RPM Engine Speed (RPM)

Evaporative Emission EVAP Evaporative Emission

Evaporative Emission Canister EVAP Canister - (Canister)

Exhaust Control System EXCS EXC System (EXCS)

Exhaust Control Valve EXCV EXC Valve (EXCV)

Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA)

Fan Control FC -

Fuel

level

Sensor -Fuel

level

Sensor, Fuel

level

Gauge

Fuel Pump FP Fuel Pump (FP)

SAE TERM FORMER SUZUKI TERM

FULL TERM ABBREVIATION

Generator GEN Generator

Ground GND Ground (GND, GRD)

Idle Speed Control ISC -

Ignition Control IC Electronic Spark Advance (ESA)

Ignition Control Module ICM -

Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature

Malfunction Indicator Lamp MIL LED Lamp

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure MAP Intake Air Pressure (lAP), Intake Vacuum

Mass Air Flow MAF Air Flow

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

Open Loop OL -

Programmable Read Only Memory PROM -

Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)

Purge Valve Purge Valve Purge Valve (SP Valve)

Random Access Memory RAM -

Read Only Memory ROM ROM

Secondary Air Injection AIR -

Secondary Throttle Control System STCS STC System (STCS)

Secondary Throttle Valve STV ST Valve (STV)

Secondary Throttle Valve Actuator STVA STV Actuator (STVA)

Throttle Body TB Throttle Body (TB)

Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

Throttle Position Sensor TP Sensor TP Sensor (TPS)

Tank Pressure Control Valve TPC Valve TPC Valve (TPCV)

Voltage Regulator VR Voltage Regulator

Volume Air Flow VAF Air Flow

WIRE COLOR

B : Black Gr : Gray R : Red

BI : Blue Lbl : Light blue W : White

Br : Brown Lg : Light green Y : Yellow

Dg : Dark green 0:Orange

G: Green P : Pink

BIBI

BIG

BIR

BI/G

BI/W

GIB

G/W

GrlB

Gr/W

OIB

OIR

P/w

RIBI

WIB

WIR

YIBI

YIR

: Black with Blue tracer

: Black with Green tracer

: Black with Red tracer

: Black with Yellow tracer

: Blue with Green tracer

: Blue with White tracer

: Green with Black tracer

: Green with White tracer

:Gray with Black tracer

:Gray with White tracer

:Orange with Black tracer

:Orange with Red tracer

:Orange with Yellow tracer

: Pink with White tracer

: Red with Blue tracer

: White with Black tracer

: White with Red tracer

:Yellow with Blue tracer

:Yellow with Red tracer

BIBr

B/Lg

B/W

BIIB

BIIR

BIN

GIBI

GrlR

GrN

OIG

O/w

PIB

RIB

R/W

WIBI

YIB

YIG

Y/w

: Black with Brown tracer

: Black with Light green tracer

: Black with White tracer

: Blue with Black tracer

: Blue with Red tracer

: Blue with Yellow tracer

: Green with Blue tracer

: Green with Yellow tracer

: Gray with Red tracer

: Gray with Yellow tracer

:Orange with Green tracer

:Orange with White tracer

: Pink with Black tracer

: Red with Black tracer

: Red with White tracer

: White with Blue tracer

:Yellow with Black tracer

:Yellow with Green tracer

:Yellow with White tracer

GENERAL

INFORMATION

1·1

GENERALWFORMATION

CONTENTS

WARNING/CAUTION/NOTE 1- 2

GENERAL PRECAUTIONS.....................................................................•.....1- 2

SUZUKI GSX-R1000K3 ('03-MODEL) .......................•..................................1- 4

SERIAL NUMBER LOCATION............•.........................................................1- 4

FUEL, OIL

AND

ENGINE COOLANTRECOMMENDATlON.........••.............1- 5

FUEL (FOR USA

AND

CANADA)...................................................•.......1- 5

FUEL (FOR OTHER COUNTRIES)••................•.................................•..•.1- 5

ENGINE OIL (FOR USA)...........................•.............................................1- 5

ENGINE OIL (FOR OTHER COUNTRIES) .....................•..•....................1- 5

BRAKE

FLUiD•...........................•....................•..................................•....1- 5

FRONT

FORK

OIL ..........................................•.......................................1- 6

ENGINE

COOLANT

..........•...........................•.......................•.................1- 6

WATER FOR MIXING ....................•..........................•.............................1- 6

ANTI-FREEZE/ENGINE

COOLANT

..........•.............................................1- 6

LIQUID

AMOUNT

OF WATER/ENGINE

COOLANT

.........................•....1- 6

BREAK-IN PROCEDURES 1- 7

CYLINDER IDENTIFICATION....................................................................•..1- 7

INFORMATION

LABELS

...........................................................•...................1- 8

SPECIFICATIONS......................................•..........•.......................•...............1- 9

DIMENSIONS

AND

DRY

MASS 1- 9

ENGINE..........................................••........................................•........•.....1- 9

DRIVE TRAIN ...................•.................••.......................•.........•......•...•......1- 9

CHASSiS.................••...................•.•...............•..................•......•.......••.•...1-10

ELECTRICAL.............................................................•.................•..........1-10

CAPACiTIES 1-10

COUNTRY

AND

AREA

CODES....................•................•..............................1-11

•

1-2

GENERAL

INFORMATION

WARNING/CAUTION/NOTE

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 the mes-

sages highlighted by these signal words.

AWARNING

Indicates apotential hazard

that

could

result in death or injury.

ICAUTION I

Indicates apotential hazard that

could

result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easieror instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS

AWARNING

*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 in forced

out-

doors.

*When

working

with

toxic

or flammable materials, make sure that

the

area

you

work

in is well-

ventilated and

that

you

all

the material manufacturer's instructions.

*Never use gasoline as a 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

to the system

for

leaks.

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