Suzuki GSX-R1000. Service Manual - part 21

1E-2 Engine Lubrication System: 

Schematic and Routing Diagram

Engine Lubrication System Chart Diagram

B947H11502001

INTAKE CAMSHAFT

INTAKE CAMSHAFT

JOURNAL HOLDER

CAM CHAIN

STARTER CLUTCH

OIL JET (#16)

CAM CHAIN TENSION ADJUSTER

#1 PISTON COOLING 

OIL JET

#1 PISTON AND 

CYLINDER WALL

#1 CRANK PIN

BEARING

#1 CRANKSHAFT 

JOURNAL BEARING

ORIFICE

GENERATOR

GENERATOR

COVER

#2 CRANKSHAFT 

JOURNAL BEARING

#3 CRANKSHAFT 

JOURNAL BEARING

#4 CRANKSHAFT 

JOURNAL BEARING

#5 CRANKSHAFT 

JOURNAL BEARING

OIL PRESSURE

SWITCH

#2 CRANK PIN

BEARING

OIL JET

(#14)

OIL FILTER

OIL COOLER

OIL PUMP

ORIFICE

OIL STRAINER

OIL PRESSUER

REGULATOR

COUNTERSHAFT

LEFT BEARING

BALANCERSHAFT

RIGHT BEARING

COUNTERSHAFT

CLUTCH PUSH

PIECE

CLUTCH PLATES

PRIMARY DRIVEN

GEAR BEARING

COUNTERSHAFT

RIGHT BEARING

DRIVESHAFT

RIGHT BEARING

#3 CRANK PIN

BEARING

#4 CRANK PIN

BEARING

#2 PISTON AND 

CYLINDER WALL

#3 PISTON AND 

CYLINDER WALL

#4 PISTON AND 

CYLINDER WALL

#2 PISTON COOLING 

OIL JET

#3 PISTON COOLING 

OIL JET

#4 PISTON COOLING 

OIL JET

EXHAUST CAMSHAFT

INTAKE CAMSHAFT JOURNALS,

CAMFACES AND TAPPETS

EXHAUST CAMSHAFT JOURNALS,

CAMFACES AND TAPPETS

SUB GALLERY

MAIN GALLERY

CRANKSHAFT

OIL PAN

EXHAUST CAMSHAFT
JOURNAL HOLDER #1

BALANCERSHAFT

BALANCERSHAFT

LEFT BEARING

DRIVESHAFT

DRIVESHAFT GEARS

AND BUSHINGS

COUNTERSHAFT GEARS

AND BUSHINGS

I947H1150001-03

Engine Lubrication System:  1E-3

Engine Lubrication Circuit Diagram

B947H11502002

I947H1150002-03

1E-4 Engine Lubrication System: 

I947H1150003-01

Engine Lubrication System:  1E-5

Diagnostic Information and Procedures

Engine Lubrication Symptom Diagnosis

B947H11504001

Oil Pressure Check

B947H11504002

Check the engine oil pressure periodically. This will give 
a good indication of the condition of the moving parts.

NOTE

Before checking the oil pressure, check the 
following.

• Oil level (Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).)

• Oil leaks (If leak is found, repair it.)

• Oil quality (If oil is discolored or 

deteriorated, replace it.)

 

1) Start the engine and check if the oil pressure 

indicator light is turned on. If the light stays on, check 
the oil pressure indicator light circuit. If the circuit is 
OK, check the oil pressure in the following manner.

2) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6).

3) Remove the oil pressure switch lead wire (1) and oil 

pressure switch (2).

4) Install the special tools to the mounting hole of the oil 

pressure switch.

Special tool

(A):  09915–74521 (Adapter hose)
(B):  09915–17410 (Oil pressure gauge 

adapter)

(C):  09915–77331 (Oil pressure gauge (1000 

kPa))

5) Install the oil pressure switch (2) to the adapter.

6) Warm up the engine as follows:

Summer: 10 min. at 2 000 r/min
Winter: 20 min. at 2 000 r/min

7) After warming up, increase the engine speed to 3 

000 r/min (Observe the tachometer), and read the oil 
pressure gauge.
If the oil pressure is lower or higher than the 
specification, the following causes may be 
considered.

Oil pressure specification
100 – 400 kPa (1.0 – 4.0 kgf/cm

2

, 14 – 57 psi) at 3 

000 r/min, Oil temp. 60 

°

C (140 

°

F)

8) Stop the engine and remove the oil pressure gauge 

and attachment. 

9) Reinstall the oil pressure switch. Refer to “Oil 

Pressure Switch Removal and Installation” 
(Page 1E-9).

Condition

Possible cause

Correction / Reference Item

Engine overheats

Insufficient amount of engine oil.

Check level and add.

Defective oil pump.

Replace.

Clogged oil circuit.

Clean.

Clogged oil cooler.

Clean or replace.

Incorrect engine oil.

Change.

Exhaust smoke is dirty or 
thick

Excessive amount of engine oil.

Check level and drain.

Engine lacks power

Excessive amount of engine oil.

Check level and drain.

1

2

I947H1150005-01

High oil pressure

Low oil pressure

• Engine oil viscosity is too 

high

• Clogged oil passage

• Combination of the 

above items

• Clogged oil filter

• Oil leakage from the oil 

passage

• Damaged O-ring

• Defective oil pump

• Combination of the 

above items

(A)

(B)

(C)

2

I947H1150036-01

1E-6 Engine Lubrication System: 

10) Check the engine oil level. Refer to “Engine Oil and 

Filter Replacement” in Section 0B (Page 0B-10).

11) Install the left side cowling. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6).

Repair Instructions

Engine Oil and Filter Replacement

B947H11506001

Refer to “Engine Oil and Filter Replacement” in Section 
0B (Page 0B-10).

Engine Oil Level Inspection

B947H11506002

Refer to “Engine Oil and Filter Replacement” in Section 
0B (Page 0B-10).

Oil Pan / Oil Pressure Regulator / Oil Strainer 
Removal and Installation

B947H11506003

NOTE

The oil pan/oil strainer/oil pressure regulator 
cannot be serviced with the engine installed 
in the frame.

 

Removal

1) Remove the engine assembly from the frame. Refer 

to “Engine Assembly Removal” in Section 1D 
(Page 1D-20).

2) Remove the plate (1).

3) Remove the oil pan (2).

4) Remove the gasket (3).

5) Remove the oil pressure regulator (4) and oil strainer 

(5).

6) Remove the O-ring (6).

Installation

Installation is in the reverse order of removal. Pay 
attention to the following points:

• Apply grease to new O-ring (1).

CAUTION

!

 

Use a new O-ring to prevent oil leakage.

 

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

• Install the oil strainer (2).

• Apply grease to new O-ring (3).

CAUTION

!

 

Use a new O-ring to prevent oil leakage.

 

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

1

2

I947H1150006-01

3

5

4

I947H1150007-01

6

I947H1150008-01

1

2

I947H1150009-01

Engine Lubrication System:  1E-7

• Push in the oil pressure regulator (4) to the oil pump 

as shown.

• Install new gasket (5).

CAUTION

!

 

Use new gasket to prevent oil leakage.

 

• Apply thread lock to the plate bolts “A”.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

• Tighten the oil pan bolts and plate bolts diagonally to 

the specified torque.

Tightening torque
Oil pan bolt:  10 N·m (1.0 kgf-m, 7.0 lbf-ft)

Oil Pressure Regulator / Oil Strainer Inspection

B947H11506004

Refer to “Oil Pan / Oil Pressure Regulator / Oil Strainer 
Removal and Installation” (Page 1E-6).

Oil Pressure Regulator

Inspect the operation of the oil pressure regulator by 
pushing the piston with a proper bar.
If the piston does not operate smoothly, replace the oil 
pressure regulator with a new one.

Oil Strainer

Clean the oil strainer if necessary.
Inspect the oil strainer body for damage. If necessary, 
replace it with a new one.

Oil Cooler / Oil Cooler Hose Inspection and 
Cleaning

B947H11506005

Refer to “Exterior Parts Removal and Installation” in 
Section 9D (Page 9D-6).

Oil Cooler Hose Inspection

Inspect the oil cooler hoses for any damage and oil 
leakage. If any defects are found, replace the oil cooler 
hose with a new one.

3

4

I947H1150010-01

5

I947H1150011-01

“A”

I947H1150012-02

I947H1150013-02

I947H1150014-01

I947H1150015-01

1E-8 Engine Lubrication System: 

Oil Cooler Inspection

1) Remove the oil cooler guard (1).

2) Inspect the oil cooler for oil leakage. If any defects 

are found, replace the oil cooler with a new one. If 
the fins are bent or dented, repair them by carefully 
straightening them with the blade of a small 
screwdriver.

3) Reinstall the removed parts.

Oil Cooler Cleaning

1) Remove the oil cooler guard (1).

2) Remove the oil cooler mounting bolts.

3) Blow out any foreign matter that is stuck in the oil 

cooler fins using compressed air.

CAUTION

!

 

• Make sure not to bend the fins when using 

compressed air.

• If compressed air is applied from the front 

side, dirt will be forced into the pores of oil 
cooler.

 

4) Reinstall the removed parts.

Oil Cooler / Oil Cooler Hose Removal and 
Installation

B947H11506006

Removal

1) Remove the side cowlings. Refer to “Exterior Parts 

Removal and Installation” in Section 9D (Page 9D-
6).

2) Drain engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

3) Remove the oil hoses (1) and (2).

4) Remove the oil cooler (3).

1

I947H1150037-02

I947H1150038-01

1

I947H1150039-01

I947H1150040-01

1

2

I947H1150016-01

3

I947H1150041-01

Engine Lubrication System:  1E-9

5) Remove the oil cooler guard (4).

Installation

Install the oil cooler and oil cooler hoses in the reverse 
order of removal. Pay attention to the following points:

• Apply thread lock to the oil cooler mounting bolt and 

tighten them securely.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

• Apply engine oil to new O-rings.

CAUTION

!

 

Replace the O-rings with new ones to prevent 
oil leakage.

 

• Apply thread lock to the oil cooler hose bolts and 

tighten them securely.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

• Pour engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

• Install the removed parts.

Oil Pressure Switch Removal and Installation

B947H11506007

Refer to “Electrical Components Location” in Section 0A 
(Page 0A-7).

Removal

1) Turn the ignition switch OFF.

2) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6).

3) Drain engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

4) Disconnect the oil pressure switch lead wire (1).

4

I947H1150017-01

I947H1150045-01

I947H1150018-01

I947H1150019-01

I947H1150044-01

1E-10 Engine Lubrication System: 

5) Remove the oil pressure switch (2).

Installation

1) Apply bond to the thread part of oil pressure switch 

and tighten oil pressure switch to the specified 
torque.

NOTE

Be careful not to apply bond to the hole of 
thread end.

 

:  Sealant 99000–31140 (SUZUKI BOND 

No.1207B or equivalent)

Tightening torque
Oil pressure switch:  14 N·m (1.4 kgf-m, 10.0 lbf-
ft)

2) Route the oil pressure switch lead wire properly and 

tighten the screw to the specified torque. Refer to 
“Wiring Harness Routing Diagram” in Section 9A 
(Page 9A-7).

Tightening torque
Oil pressure switch lead wire screw (a):  1.5 N·m 
(0.15 kgf-m, 1.1 lbf-ft)

3) Pour engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

4) Install the removed parts.

Oil Pressure Switch Inspection

B947H11506008

Refer to “Oil Pressure Indicator Inspection” in Section 9C 
(Page 9C-6).

Oil Jet Removal and Installation

B947H11506009

Piston Cooling Oil Jet
Removal

1) Remove the engine assembly. Refer to “Engine 

Assembly Removal” in Section 1D (Page 1D-20).

2) Remove the Crankshaft assembly. Refer to “Engine 

Bottom Side Disassembly” in Section 1D (Page 1D-
49).

3) Remove the piston cooling oil jets (1) from the upper 

crankcase.

Installation

Installation is in the reverse order of removal. Pay 
attention to the following points:

• Fit new O-ring (1) to each piston cooling oil jet and 

apply engine oil to it.

CAUTION

!

 

Use new O-rings to prevent oil pressure 
leakage.

 

1

2

I947H1150020-01

I718H1140233-01

(a)

I947H1150021-02

1

I947H1150022-01

1

I947H1150023-01

Engine Lubrication System:  1E-11

• Apply a small quantity of thread lock to the bolts and 

tighten them to the specified torque.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

Tightening torque
Piston cooling oil jet bolt (a):  10 N·m (1.0 kgf-m, 
7.0 lbf-ft)

Oil Jet (For Cam Chain Tension Adjuster)
Removal

1) Remove the throttle body. Refer to “Throttle Body 

Removal and Installation” in Section 1D (Page 1D-
10).

2) Remove the regulator/rectifier. Refer to “Regulator / 

Rectifier Removal and Installation” in Section 1J 
(Page 1J-7).

3) Remove the cam chain tension adjuster (1). Refer to 

“Engine Top Side Disassembly” in Section 1D 
(Page 1D-26).

4) Remove the oil jet (2) (for cam chain tension 

adjuster).

Installation

Installation is in the reverse order of removal. Pay 
attention to the following points:

• Apply engine oil to the O-ring.

CAUTION

!

 

Use a new O-ring to prevent oil leakage.

 

• Install the cam chain tension adjuster. Refer to 

“Engine Top Side Assembly” in Section 1D (Page 1D-
28).

• Install the regulator/rectifier. Refer to “Regulator / 

Rectifier Removal and Installation” in Section 1J 
(Page 1J-7).

• Install the throttle body. Refer to “Throttle Body 

Removal and Installation” in Section 1D (Page 1D-
10).

(a)

I947H1150024-01

1

I947H1150042-01

2

I947H1150043-01

I947H1150025-01

1E-12 Engine Lubrication System: 

Oil Jet (For Transmission)
Removal

1) Remove the engine assembly. Refer to “Engine 

Assembly Removal” in Section 1D (Page 1D-20).

2) Separate the crankcases, upper and lower. Refer to 

“Engine Bottom Side Disassembly” in Section 1D 
(Page 1D-49).

3) Remove the oil jet (1) (for transmission) from the 

lower crankcase.

Installation

Installation is in the reverse order of removal. Refer to 
“Engine Bottom Side Assembly” in Section 1D 
(Page 1D-56).

Oil Jet Inspection

B947H11506010

Refer to “Oil Jet Removal and Installation” (Page 1E-10).

Oil Jet

Make sure that the oil jets are not clogged. If they are 
clogged, clean their oil passage using a wire of the 
proper size and compressed air.

Oil Pump Removal and Installation

B947H11506011

NOTE

Be careful not to drop any parts into the 
crankcase.

 

Removal

1) Remove the oil pan, oil pressure regulator and oil 

strainer. Refer to “Oil Pan / Oil Pressure Regulator / 
Oil Strainer Removal and Installation” (Page 1E-6).

2) Remove the oil pump driven gear bolt (1).

3) Remove the oil pump driven sprocket (2).

4) Remove the washer (3).

5) Remove the oil pump (4).

6) Remove the O-ring (5) and dowel pins.

1. Piston cooling jet

2. Oil jet (For transmission)

3. Oil jet (For cam chain tension adjuster)

1

I947H1150026-01

1

2

3

I947H1150027-01

1

2

3

I947H1150028-01

4

I947H1150029-01

5

I947H1150030-01

Engine Lubrication System:  1E-13

Installation

1) Install the dowel pins.

2) Apply grease to new O-ring.

CAUTION

!

 

Use a new O-ring to prevent oil leakage.

 

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

3) Install the oil pump.

NOTE

Engage the oil pump shaft end with the water 
pump shaft slot.

 

4) Tighten the oil pump mounting bolts to the specified 

torque.

Tightening torque
Oil pump mounting bolt (a):  10 N·m (1.0 kgf-m, 
7.0 lbf-ft)

5) Install the washer (1).

6) Install the oil pump driven sprocket (2) with the chain 

(3).

7) Apply a small quantity of thread lock to the oil pump 

driven sprocket bolt (4) and tighten it to the specified 
torque.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

Tightening torque
Oil pump driven sprocket bolt (b):  10 N·m (1.0 
kgf-m, 7.0 lbf-ft)

8) Install the oil pan, oil strainer and oil pressure 

regulator. Refer to “Oil Pan / Oil Pressure Regulator / 
Oil Strainer Removal and Installation” (Page 1E-6).

I947H1150031-01

I947H1150032-01

(a)

I947H1150033-01

1

2

3

(b)

4

I947H1150034-01

1E-14 Engine Lubrication System: 

Oil Pump Inspection

B947H11506012

Inspect the oil pump in the following procedures:

1) Remove the oil pump. Refer to “Oil Pump Removal 

and Installation” (Page 1E-12).

2) Rotate the oil pump by hand and check that it moves 

smoothly. If it does not move smoothly, replace the 
oil pump assembly.

CAUTION

!

 

Do not attempt to disassemble the oil pump.
The oil pump is available only as an 
assembly.

 

3) Install the oil pump. Refer to “Oil Pump Removal and 

Installation” (Page 1E-12).

Oil Pump Drive Sprocket Removal and 
Installation

B947H11506013

Refer to “Engine Bottom Side Disassembly” in Section 
1D (Page 1D-49) and “Engine Bottom Side Assembly” in 
Section 1D (Page 1D-56).

Specifications

Service Data

B947H11507001

Oil Pump

Oil

Tightening Torque Specifications

B947H11507002

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C 
(Page 0C-9).

I947H1150035-01

Item

Standard

Limit

Oil pressure (at 60 

°

C, 140 

°

F)

100 – 400 kPa (1.0 – 4.0 kgf/cm

2

, 14 – 57 psi)

at 3 000 r/min

—

Item

Specification

Note

Engine oil type

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Engine oil capacity

Change

2 800 ml (3.0/2.5 US/lmp qt)

Filter change

3 300 ml (3.5/2.9 US/lmp qt)

Overhaul

3 600 ml (3.8/3.2 US/lmp qt)

Fastening part

Tightening torque

Note

N

⋅

m

kgf-m

lbf-ft

Oil pan bolt

10

1.0 

7.0 

)

(Page 1E-7)

Oil pressure switch

14

1.4 

10.0 

)

(Page 1E-10)

Oil pressure switch lead wire screw

1.5

0.15 

1.1 

)

(Page 1E-10)

Piston cooling oil jet bolt

10

1.0 

7.0 

)

(Page 1E-11)

Oil pump mounting bolt

10

1.0 

7.0 

)

(Page 1E-13)

Oil pump driven sprocket bolt

10

1.0 

7.0 

)

(Page 1E-13)

Engine Lubrication System:  1E-15

Special Tools and Equipment

Recommended Service Material

B947H11508001

Special Tool

B947H11508002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or 
equivalent

P/No.: 99000–25010

)

(Page 1E-6) / 

)

(Page 1E-

6) / 

)

(Page 1E-13)

Sealant

SUZUKI BOND No.1207B or 
equivalent

P/No.: 99000–31140

)

(Page 1E-10)

Thread lock cement

THREAD LOCK CEMENT SUPER 
“1322” or equivalent

P/No.: 99000–32110

)

(Page 1E-7) / 

)

(Page 1E-

9) / 

)

(Page 1E-9) / 

)

(Page 1E-11) / 

)

(Page 1E-13)

09915–17410

09915–74521

Oil pressure gauge adapter

Adapter hose

)

(Page 1E-5)

)

(Page 1E-5)

09915–77331
Oil pressure gauge (1000 
kPa)

)

(Page 1E-5)

1F-1 Engine Cooling System: 

Engine

Engine Cooling System

Precautions

Precautions for Engine Cooling System

B947H11600001

WARNING

!

 

• You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. 

After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a 
quarter turn to allow pressure to escape and then turn the cap all the way off.

• The engine must be cool before servicing the cooling system.

• Coolant is harmful:

– If it comes in contact with skin or eyes, flush with water.

– If swallowed accidentally, induce vomiting and call physician immediately.

– Keep it away from children.

 

Precautions for Engine Coolant

B947H11600002

Refer to “Engine Coolant Recommendation” in Section 0A (Page 0A-4).

General Description

Engine Coolant Description

B947H11601001

CAUTION

!

 

• Use a high quality ethylene glycol base 

anti-freeze, mixed with distilled water. Do 
not mix an alcohol base anti-freeze and 
different brands of anti-freeze.

• Do not put in more than 60% anti-freeze or 

less than 50%. (Refer to Fig. 1 and 2.)

 

At the time of manufacture, the cooling system is filled 
with a 50:50 mixture of distilled water and ethylene 
glycol anti-freeze. This 50:50 mixture will provide the 
optimum corrosion protection and excellent heat 
protection, and will protect the cooling system from 
freezing at temperatures above –31 

°

C (–24 

°

F).

If the vehicle is to be exposed to temperatures below –
31 

°

C (–24 

°

F), this mixing ratio should be increased up 

to 55% or 60% according to the figure.

Anti-freeze Proportioning Chart

Fig. 1: Engine coolant density-freezing point curve

Fig. 2: Engine coolant density-boiling point curve

Anti-freeze density

Freezing point

50%

–31 

°

C (–24 

°

F)

55%

–40 

°

C (–40 

°

F)

60%

–55 

°

C (–67 

°

F)

I310G1160001-01

I310G1160002-01

Engine Cooling System:  1F-2

Schematic and Routing Diagram

Cooling Circuit Diagram

B947H11602001

WATER

PUMP

RADIATOR

ECT SENSOR

THERMOSTAT

CYLINDER HEAD

CYLINDER

RESERVOIR

TANK

I947H1160001-02