Suzuki GSX-R1000. Service Manual - part 22

1F-3 Engine Cooling System: 

Water Hose Routing Diagram

B947H11602002

“I”

“C”

“F”

“H”

“A”

“A”

“A”

“B”

“B”

“G”

“ a ”

“ b ”

(a)

(b)

“B”

1

(c)

“K”

“A”

“J”

“D”

2

3

4

“E”

I947H1160053-03

1. Thermostat air bleeder hole

“D”: Clamp end should face right side.

“K”: Screw head should face left side.

2. Cushion

“E”: Cut off the excess tip of the clamp.

“a”: 2 – 8 mm (0.08 – 0.31 in)

3. O-ring

“F”: Screw head should face right side.

“b”: Clearance

4. Radiator heat guard

: Be careful not to damage the pawls when removing.

“G”: Screw head should face backward.

: 6 N

⋅

m (0.6 kgf-m, 4.5 lbf-ft)

“A”: Yellow marking

“H”: Clamp end should face upward.

: 10 N

⋅

m (1.0 kgf-m, 0.7 lbf-ft)

“B”: White marking

“I”: Clamp end should face left side.

: 13 N

⋅

m (1.3 kgf-m, 9.5 lbf-ft)

“C”: Clamp end should face downward.

“J”: Screw head should face forward.

: :Apply engine oil.

Engine Cooling System:  1F-4

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis

B947H11604001

Repair Instructions

Cooling Circuit Inspection

B947H11606001

WARNING

!

 

• Do not open the radiator cap when the 

engine is hot, as you may be injured by 
escaping hot liquid or vapor.

• When removing the radiator cap tester, put 

a rag on the filler to prevent the engine 
coolant from spraying out.

 

Inspect the cooling circuit in the following procedures:

1) Remove the right side cowling. Refer to “Exterior 

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

2) Remove the radiator cap (1) and connect the 

radiator tester (2) to the filler.

3) Pressurize the cooling system with 120 kPa (1.2 kgf/

cm, 17.6 psi) of pressure, and then check if it holds 
the pressure for 10 seconds.

CAUTION

!

 

Do not exceed the radiator cap release 
pressure, or the radiator cap and 
subsequently the radiator, can be damaged.

 

4) After finishing the cooling circuit inspection, reinstall 

the removed parts.

Condition

Possible cause

Correction / Reference Item

Engine overheats

Not enough engine coolant.

Add engine coolant.

Radiator core clogged with dirt or scale.

Clean.

Faulty cooling fan.

Repair or replace.

Defective cooling fan relay, or open-or-
short circuited.

Repair or replace.

Clogged water passage.

Clean.

Air trapped in the cooling circuit.

Bleed air.

Defective water pump.

Replace.

Use of incorrect engine coolant.

Replace.

Defective thermostat.

Replace.

Defective ECT sensor.

Replace.

Defective ECM.

Replace.

Damaged ISC valve.

Replace.

Incorrect ISC learning.

Reset learned value.

Engine over cools

Defective cooling fan relay, or open-or-
short circuited.

Repair or replace.

Extremely cold weather.

Put on radiator cover.

Defective thermostat.

Replace.

Defective ECT sensor.

Replace.

Defective ECM.

Replace.

1

I947H1160002-02

2

I815H1160002-01

1F-5 Engine Cooling System: 

Radiator Cap Inspection

B947H11606002

Inspect the radiator cap in the following procedures:

1) Remove the radiator cap. Refer to “Cooling Circuit 

Inspection” (Page 1F-4).

2) Attach the radiator cap (1) to the radiator tester (2) 

as shown.

3) Slowly apply pressure to the radiator cap.

If the radiator cap does not hold the pressure for at 
least 10 seconds, replace it with a new one.

Radiator cap release pressure
93 – 123 kPa (0.9 – 1.2 kgf/cm

2

, 13.2 – 17.5 psi)

4) After finishing the radiator cap inspection, reinstall 

the removed parts.

Radiator Inspection and Cleaning

B947H11606003

Radiator Hose Inspection

Refer to “Cooling System Inspection” in Section 0B 
(Page 0B-12).

Radiator Inspection

Inspect the radiator for water leaks. If any defects are 
found, replace the radiator with a new one.
If the fins are bent or dented, repair them by carefully 
straightening them with the blade of a small screwdriver.

Radiator Cleaning

Blow out any foreign matter that is stuck in the radiator 
fins using compressed air.

CAUTION

!

 

• Make sure not to bend the fins when using 

compressed air.

• Always apply compressed air from the 

engine side. If compressed air is applied 
from the front side, dirt will be forced into 
the pores of radiator.

 

1) Remove the inner under cowlings. Refer to “Exterior 

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

2) Disconnect the cooling fan motor lead wire coupler 

(1).

3) Remove the oil cooler (2) from the bracket.

I718H1160033-01

I947H1160003-01

1

I947H1160005-01

2

I947H1160006-02

Engine Cooling System:  1F-6

4) Remove the radiator mounting bolts.

5) Move the radiator forward.

6) Apply compressed air from the engine side.

7) Tighten the upper radiator mounting bolts.

8) Apply thread lock to the radiator bracket bolts and 

tighten all bolts securely.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

9) Apply thread lock to the oil cooler bolts and tighten 

them securely.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

10) Reinstall the removed parts.

Radiator / Cooling Fan Motor Removal and 
Installation

B947H11606004

Removal

1) Remove the inner under cowlings. Refer to “Exterior 

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

2) Drain engine coolant. Refer to “Cooling System 

Inspection” in Section 0B (Page 0B-12).

3) Disconnect the reservoir tank inlet hose (1) and 

water air bleed hose (2).

4) Remove the radiator reservoir tank (3).

5) Disconnect the radiator inlet hose (4).

6) Disconnect the cooling fan motor coupler (5).

I947H1160007-01

I947H1160008-02

I947H1160051-01

I947H1160056-01

I947H1160057-01

1

2

3

I947H1160004-02

5

4

I947H1160009-02

1F-7 Engine Cooling System: 

7) Remove the oil cooler (6) from the bracket.

8) Remove the radiator assembly by removing the 

bolts.

9) Remove the radiator outlet hose (7) and cooling fan 

motor (8) from the radiator.

Installation

Install the radiator in the reverse order of removal. Pay 
attention to the following points:

• Install the radiator and oil cooler to their bracket. Refer 

to “Radiator Inspection and Cleaning” (Page 1F-5).

• Apply thread lock to the reservoir tank bolt and tighten 

it securely.

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

• Connect the radiator hoses securely. Refer to “Water 

Hose Routing Diagram” (Page 1F-3).

• Pour engine coolant. Refer to “Cooling System 

Inspection” in Section 0B (Page 0B-12).

• Bleed air from the cooling circuit. Refer to “Cooling 

System Inspection” in Section 0B (Page 0B-12).

Water Hose Inspection

B947H11606005

Inspect the water hoses in the following procedures:

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

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

2) Check the water hoses for crack, damage or engine 

coolant leakage. If any defect is found, replace the 
water hose with a new one.

6

I947H1160010-01

I947H1160011-01

I947H1160012-02

7

8

I947H1160013-01

I947H1160058-01

Engine Cooling System:  1F-8

3) Any leakage from the connecting section should be 

corrected by proper tightening. Refer to “Water Hose 
Routing Diagram” (Page 1F-3).

4) After finishing the water hoses inspection, reinstall 

the removed parts.

Water Hose Removal and Installation

B947H11606006

Removal

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

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

2) Drain engine coolant. Refer to “Cooling System 

Inspection” in Section 0B (Page 0B-12).

3) Lift and support the fuel tank. Refer to “Fuel Tank 

Removal and Installation” in Section 1G (Page 1G-
9).

4) Remove the water hose as shown in the water hose 

routing diagram. Refer to “Water Hose Routing 
Diagram” (Page 1F-3).

Installation

1) Install the water hose as shown in the water hose 

routing diagram. Refer to “Water Hose Routing 
Diagram” (Page 1F-3).

2) Install the fuel tank. Refer to “Fuel Tank Removal 

and Installation” in Section 1G (Page 1G-9).

3) Pour engine coolant and bleed air from the cooling 

circuit. Refer to “Cooling System Inspection” in 
Section 0B (Page 0B-12).

4) Install the side cowlings. Refer to “Exterior Parts 

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

Radiator Reservoir Tank Inspection

B947H11606007

Inspect the radiator reservoir tank in the following 
procedures:

1) Remove the right side cowling. Refer to “Exterior 

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

2) Inspect the radiator reservoir tank (1) for leaks. If any 

defects are found, replace the radiator reservoir tank 
with a new one.

3) Reinstall the removed parts.

Radiator Reservoir Tank Removal and 
Installation

B947H11606008

Removal

1) Remove the right side cowling. Refer to “Exterior 

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

2) Disconnect the reservoir tank inlet hose (1) from the 

reservoir tank (2) and drain the engine coolant.

3) Remove the reservoir tank (2).

I947H1160014-02

I947H1160015-01

I947H1160016-01

1

I947H1160017-02

1F-9 Engine Cooling System: 

4) Disconnect the reservoir tank overflow hose (3).

Installation

1) Install the reservoir tank. Refer to “Radiator / Cooling 

Fan Motor Removal and Installation” (Page 1F-6).

2) Fill the reservoir tank with engine coolant to the 

upper level. Refer to “Cooling System Inspection” in 
Section 0B (Page 0B-12).

3) Install the right side cowling. Refer to “Exterior Parts 

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

Cooling Fan Inspection

B947H11606009

Cooling fan operating temperature
Standard
(ON 

→

 OFF): Approx. 100 

°

C (212 

°

F)

(OFF 

→

 ON): Approx. 105 

°

C (221 

°

F)

Inspect the cooling fan in the following procedures:

1) Disconnect the cooling fan motor coupler (1).

2) Test the cooling fan motor for load current with an 

ammeter connected as shown in the figure.
If the fan motor does not turn, replace the cooling fan 
assembly with a new one. Refer to “Radiator / 
Cooling Fan Motor Removal and Installation” 
(Page 1F-6).

NOTE

• When making this test, it is not necessary 

to remove the cooling fan.

• Make sure that the battery has a capacity 

enough to supply the motor with 12 V.

• With the motor running at full speed, the 

ammeter should indicate an amperage not 
higher than 5 A.

 

3) Connect the cooling fan motor coupler.

Cooling Fan Relay Inspection

B947H11606010

Inspect the fan relay in the following procedures:

1) Remove the frame covers. Refer to “Exterior Parts 

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

2) Remove the cooling fan relay (1).

1

2

3

I947H1160018-03

1

I947H1160019-01

2. Fan motor

3. Ammeter

4. Battery

2

3

4

I718H1160048-01

1

I947H1160052-01

Engine Cooling System:  1F-10

3) First check the insulation between “A” and “B” 

terminals with tester. Then apply 12 volts to “C” and 
“D” terminals, (+) to “C” and (–) to “D”, and check the 
continuity between “A” and “B”.
If there is no continuity, replace it with a new one.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication set
Continuity test (

)

4) Reinstall the removed parts.

ECT Sensor Removal and Installation

B947H11606011

Refer to “ECT Sensor Removal and Installation” in 
Section 1C (Page 1C-4).

ECT Sensor Inspection

B947H11606012

Refer to “ECT Sensor Inspection” in Section 1C 
(Page 1C-4).

Thermostat Removal and Installation

B947H11606013

Removal

1) Drain a small amount of engine coolant. Refer to 

“Cooling System Inspection” in Section 0B 
(Page 0B-12).

2) Lift and support the fuel tank. Refer to “Fuel Tank 

Removal and Installation” in Section 1G (Page 1G-
9).

3) Remove the thermostat cover (1).

4) Remove the thermostat (2).

Installation

Install the thermostat in the reverse order of removal. 
Pay attention to the following points:

• Install the thermostat.

NOTE

Air bleeder hole “A” of the thermostat faces 
upside.

 

• Tighten the thermostat cover bolts to the specified 

torque.

Tightening torque
Thermostat cover bolt (a):  10 N·m (1.0 kgf-m, 7.0 
lbf-ft)

• Pour engine coolant and bleed air from the cooling 

circuit. Refer to “Cooling System Inspection” in 
Section 0B (Page 0B-12).

“A”

“B”

“C”

“D”

I718H1160006-03

1

I947H1160020-02

2

I947H1160021-02

“A”

I947H1160022-02

(a)

I947H1160023-01

1F-11 Engine Cooling System: 

Thermostat Inspection

B947H11606014

Inspect the thermostat in the following procedures:

1) Remove the thermostat. Refer to “Thermostat 

Removal and Installation” (Page 1F-10).

2) Inspect the thermostat pellet for signs of cracking.

3) Test the thermostat at the bench for control action.

CAUTION

!

 

• Do not contact the thermostat (1) and 

column thermometer (2) with a pan.

• As the thermostat operating response to 

water temperature change is gradual, do 
not raise water temperature too quickly.

• The thermostat with its valve open even 

slightly under normal temperature must be 
replaced.

 

4) Immerse the thermostat (1) in the water contained in 

a beaker and note that the immersed thermostat is in 
suspension.

5) Heat the water by placing the beaker on a stove and 

observe the rising temperature on a thermometer 
(2).

6) Read the thermometer just when opening the 

thermostat. If this reading, which is the temperature 
level at which the thermostat valve begins to open, is 
out of the standard value, replace the thermostat 
with a new one.

Thermostat valve opening temperature
Standard: Approx. 82 

°

C (180 

°

F)

7) Keep on heating the water to raise its temperature.

8) Just when the water temperature reaches specified 

value, the thermostat valve should have been lifted 
by at least 8 mm (0.31 in). A thermostat failing to 
satisfy either of the two requirements (start-to-open 
temperature and valve lift) must be replaced.

Thermostat valve lift “a”
Standard: Over 8 mm (0.31 in) and at 95 

°

C (203 

°

F)

9) Install the thermostat. Refer to “Thermostat Removal 

and Installation” (Page 1F-10).

“A”: String

“B”: Water

I947H1160024-01

I705H1160030-03

I705H1160031-04

Engine Cooling System:  1F-12

Water Pump Components

B947H11606015

1

2

5

FWD

FWD

(d)

3

(a)

(c)

(b)

4

I947H1160055-02

1. Impeller

: 8 N

⋅

m (0.8 kgf-n, 6.0 Ib-ft)

: Apply engine coolant.

2. Mechanical seal

: 10 N

⋅

m (1.0 kgf-n, 7.0 Ib-ft)

: Apply molybdenum oil solution.

3. Oil seal

: 6 N

⋅

m (0.6 kgf-n, 4.5 Ib-ft)

: Do not reuse.

4. O-ring

: 13 N

⋅

m (1.3 kgf-n, 9.5 Ib-ft)

5. O-ring

: Apply grease.

1F-13 Engine Cooling System: 

Water Pump Construction

B947H11606016

Water Pump Removal and Installation

B947H11606017

Removal

NOTE

Before draining engine oil and engine 
coolant, inspect engine oil and coolant 
leakage between the water pump and 
crankcase. If engine oil is leaking, visually 
inspect the oil seal and O-ring. If engine 
coolant is leaking, visually inspect the 
mechanical seal and seal washer. Refer to 
“Water Pump Related Parts Inspection” 
(Page 1F-17).

 

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

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

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

and Filter Replacement” in Section 0B (Page 0B-10) 
and “Cooling System Inspection” in Section 0B 
(Page 0B-12).

3) Disconnect the water bypass hose (1).

4) Remove the water pump (2).

Installation

Install the water pump in the reverse order of removal. 
Pay attention to the following points:

• Apply grease to the O-ring.

CAUTION

!

 

Replace the O-ring with the a new one.

 

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

1

2

3

5

4

(b)

(a)

I947H1160054-02

1. Impeller 

5. O-ring

: Apply engine coolant.

2. Mechanical seal

: 8 N

⋅

m (0.8 kgf-m, 6.0 lbf-ft)

: Apply molybdenum oil solution.

3. Oil seal

: 10 N

⋅

m (1.0 kgf-m, 7.0 lbf-ft)

: Do not reuse.

4. O-ring

: Apply grease.

1

2

I947H1160025-02

Engine Cooling System:  1F-14

• Install the water pump assembly with the slot of the 

pump shaft end “A” securely engaged with the flat “B” 
of the oil pump shaft.

• Tighten the water pump mounting bolts (1) to the 

specified torque.

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

• Connect the water hoses securely. Refer to “Water 

Hose Routing Diagram” (Page 1F-3).

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

Filter Replacement” in Section 0B (Page 0B-10) and 
“Cooling System Inspection” in Section 0B (Page 0B-
12).

• Bleed air from the cooling circuit. Refer to “Cooling 

System Inspection” in Section 0B (Page 0B-12).

Water Pump Disassembly and Assembly

B947H11606018

Refer to “Water Pump Removal and Installation” 
(Page 1F-13).

Disassembly

1) Remove the air bleeder bolt (1) if necessary.

2) Remove the water pump case screws.

3) Remove the O-ring (2).

4) Hold the impeller (3) with water pump pliers and 

remove the impeller securing bolt (4).

“A”

“B”

I947H1160026-01

(a)

1

I947H1160027-03

1

I947H1160028-01

I947H1160029-01

2

I947H1160030-01

1F-15 Engine Cooling System: 

5) Remove the impeller (3).

6) Remove the mechanical seal ring (5) and rubber 

seal (6) from the impeller.

7) Remove the O-ring (7), impeller shaft (8) and washer 

(9) from the holder.

8) Remove the mechanical seal (10) with the special 

tool.

NOTE

If there is no abnormal condition, the 
mechanical seal removal is not necessary.

 

Special tool

(A):  09921–20240 (Bearing remover set)

9) Remove the oil seal (11).

NOTE

If there is no abnormal condition, the oil seal 
removal is not necessary.

 

Assembly

1) Install the oil seal with the special tool.

CAUTION

!

 

The removed oil seal must be replaced with a 
new one.

 

NOTE

The stamped mark on the oil seal should face 
mechanical seal side.

 

Special tool

(A):  09913–70210 (Bearing installing set (10 

– 75 

Φ

))

3

4

I947H1160031-01

5

6

I947H1160032-01

7

8

9

I947H1160033-01

(A)

10

I947H1160034-01

11

I947H1160035-01

(A)

I947H1160036-01

Engine Cooling System:  1F-16

2) Apply a small quantity of the grease to the oil seal 

lip.

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

3) Install a new mechanical seal using a suitable size 

socket wrench.

CAUTION

!

 

The removed mechanical seal must be 
replaced with a new one.

 

NOTE

On new mechanical seals, the sealer “A” has 
been applied.

 

4) Apply molybdenum solution to the impeller shaft (1) 

and washer (2).

M/O:  Molybdenum oil  (MOLYBDENUM OIL 
SOLUTION)

5) Install the impeller shaft (1) and washer (2) to the 

holder.

6) Install the rubber seal (3) into the impeller.

7) After wiping off the oily or greasy matter from the 

mechanical seal ring (4), install it into the impeller.

NOTE

The paint marked side “B” of mechanical seal 
ring faces the rubber seal.

 

8) Install the washer (5) and seal washer (6) onto the 

impeller securing bolt.

NOTE

The metal side “C” of seal washer and the 
curved side “D” of washer face the impeller 
securing bolt head.

 

9) Install the impeller (7).

I947H1160037-01

“A”

I947H1160038-01

I947H1160039-01

1

2

I947H1160040-01

3

4

“B”

I947H1160041-01

5

6

“C”

“D”

I947H1160042-01

1F-17 Engine Cooling System: 

10) Hold the impeller with water pump pliers and tighten 

the impeller securing bolt to the specified torque.

Tightening torque
Impeller securing bolt (a):  8 N·m (0.8 kgf-m, 6.0 
lbf-ft)

11) Install new O-ring (8) and apply engine coolant to it.

CAUTION

!

 

Use a new O-ring to prevent engine coolant 
leakage.

 

12) Tighten the water pump case screws to the specified 

torque.

Tightening torque
Water pump case screw:  6 N·m (0.6 kgf-m, 4.5 
lbf-ft)

13) Tighten the water pump air bleeder bolt (9) to the 

specified torque.

CAUTION

!

 

Use a new gasket washer to prevent engine 
coolant leakage.

 

Tightening torque
Water pump air bleeder bolt (b):  13 N·m (1.3 kgf-
m, 9.5 lbf-ft)

Water Pump Related Parts Inspection

B947H11606019

Refer to “Water Pump Disassembly and Assembly” 
(Page 1F-14).

Mechanical Seal

Visually inspect the mechanical seal for damage, with 
particular attention given to the sealing face.
Replace the mechanical seal that shows indications of 
leakage.

Oil Seal

Visually inspect the oil seal for damage, with particular 
attention given to the lip.
Replace the oil seal that shows indications of leakage.

(a)

7

I947H1160043-02

8

I947H1160044-02

(b)

9

I947H1160045-01

I947H1160046-01

I947H1160047-01

Engine Cooling System:  1F-18

Seal Washer

Visually inspect the seal washer for damage, with 
particular attention given to the sealing face.
Replace the seal washer that shows indications of 
leakage.

Impeller / Shaft

Visually inspect the impeller and its shaft for damage.
Replace the impeller or shaft if necessary.

Impeller Shaft Journal

Visually inspect the journal for damage or scratch.
Replace the holder if necessary.

Specifications

Service Data

B947H11607001

Thermostat + Radiator + Fan + Coolant

I947H1160048-01

I947H1160049-01

I947H1160050-01

Item

Specification

Note

Thermostat valve opening 
temperature

Approx. 82 

°

C (180 

°

F)

—

Thermostat valve lift

Over 8 mm (0.31 in) and at 95 

°

C (203 

°

F)

—

ECT sensor resistance

20 

°

C

 (68 

°

F)

Approx. 2.45 k

Ω

—

50 

°

C

 (122 

°

F)

Approx. 0.811 k

Ω

—

80 

°

C

 (176 

°

F)

Approx. 0.318 k

Ω

—

110 

°

C

 (230 

°

F)

Approx. 0.142 k

Ω

—

Radiator cap valve opening 
pressure

93 – 123 kPa (0.9 – 1.2 kgf/cm

2

, 13.2 – 17.5 psi)

—

Cooling fan operating temperature

OFF 

→

 ON

Approx. 105 

°

C (221 

°

F)

—

ON 

→

 OFF

Approx. 100 

°

C (212 

°

F)

—

Engine coolant type

Use an anti-freeze/coolant compatible with aluminum 
radiator, mixed with distilled water only, at the ratio of 50:50.

—

Engine coolant

Reservoir tank 

side

Approx. 250 ml (0.3/0.2 US/lmp qt)

—

Engine side

Approx. 2 500 ml (2.6/2.2 US/lmp qt)

—