Suzuki GSX-R1000. Service Manual - part 23

1F-19 Engine Cooling System: 

Tightening Torque Specifications

B947H11607002

NOTE

The specified tightening torque is described in the following.
“Water Hose Routing Diagram” (Page 1F-3)
“Water Pump Components” (Page 1F-12)
“Water Pump Construction” (Page 1F-13)

 

Reference:

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

Special Tools and Equipment

Recommended Service Material

B947H11608001

NOTE

Required service material is also described in the following.
“Water Hose Routing Diagram” (Page 1F-3)
“Water Pump Components” (Page 1F-12)
“Water Pump Construction” (Page 1F-13)

 

Special Tool

B947H11608002

Fastening part

Tightening torque

Note

N

⋅

m

kgf-m

lbf-ft

Thermostat cover bolt

10

1.0 

7.0 

)

(Page 1F-10)

Water pump mounting bolt

10

1.0 

7.0 

)

(Page 1F-14)

Impeller securing bolt

8

0.8 

6.0 

)

(Page 1F-17)

Water pump case screw

6

0.6 

4.5 

)

(Page 1F-17)

Water pump air bleeder bolt

13

1.3 

9.5 

)

(Page 1F-17)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or 
equivalent

P/No.: 99000–25010

)

(Page 1F-13) / 

)

(Page 1F-16)

Molybdenum oil

MOLYBDENUM OIL SOLUTION

—

)

(Page 1F-16)

Thread lock cement

THREAD LOCK CEMENT SUPER 
“1322” or equivalent

P/No.: 99000–32110

)

(Page 1F-6) / 

)

(Page 1F-

6) / 

)

(Page 1F-7)

09900–25008

09913–70210

Multi circuit tester set

Bearing installing set (10 – 
75 

Φ

)

)

(Page 1F-10)

)

(Page 1F-15)

09921–20240
Bearing remover set

)

(Page 1F-15)

Fuel System:  1G-1

Engine

Fuel System

Precautions

Precautions for Fuel System

B947H11700001

WARNING

!

 

• Keep away from fire or spark.

• During disassembling, use care to minimize spillage of gasoline.

• Spilled gasoline should be wiped off immediately.

• Work in a well-ventilated area.

• For E-33 models, drain fuel from the fuel tank before disconnecting the fuel feed hose to prevent fuel 

leakage.

 

CAUTION

!

 

• To prevent the fuel system (fuel tank, fuel hose, etc.) from contamination with foreign particles, blind 

all openings.

• After removing the throttle body, tape the cylinder intake section to prevent foreign particles from 

entering.

 

1G-2 Fuel System: 

General Description

Fuel Injection System Description

B947H11701001

Fuel System

The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipes 
(5) including fuel injectors (6) and (7), fuel pressure regulator (8). There is no fuel return hose. The fuel in the fuel tank 
is pumped up by the fuel pump and pressurized fuel flows into the injectors installed in the fuel delivery pipe. Fuel 
pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injectors (the fuel pressure 
in the fuel delivery pipe) is always kept at absolute fuel pressure of approx. 294 kPa (2.9 kgf/cm

2

, 41.8 psi), the fuel is 

injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the 
ECM.
The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

1

2

3

5

6

7

“C”

4

“A”

“B”

8

I947H1170019-03

1. Fuel tank

4. Fuel feed hose

7. Secondary fuel injector

“B”: Pressurized fuel

2. Fuel pump

5. Fuel delivery pipe

8. Fuel pressure regulator

“C”: Relieved fuel

3. Fuel mesh filter

6. Primary fuel injector

“A”: Pre-pressurized fuel

Fuel System:  1G-3

Schematic and Routing Diagram

Fuel Tank Drain Hose and Breather Hose Routing Diagram

B947H11702001

1

2

2

3

5

6

“C”

“D”

“E”

“F”

4

“A”

“B”

“G”

“ a ”

“ b ”

“ c ”

“H”

“I”

I947H1170020-02

1. Fuel tank water drain hose

“A”: White marking

“G”: Stick the hose clamp along the line behind the cowling.

2. Fuel tank breather hose No. 1

“B”: Set the hose end to the root of tank nipple.

“H”: Clamp the hoses at marking point. Match the length of 

hoses.

3. Fuel tank breather hose No. 2

“C”: Match the direction of 3-way joint and hoses.

“I”: Pass the hoses in front of the rear brake reservoir.

4. Fuel tank breather hose No. 3

“D”: Arrange the hoses in parallel.

“a”: 30 – 45

°

5. 3-way joint

“E”: Face the clamp end forward. Cut off the 

excess tip of the clamp.

“b”: 10 – 30 mm (0.4 – 1.2 in)

6. Frame

“F”: Set the hoses with the white marking inside.

“c”: 50 mm (2.0 in)

1G-4 Fuel System: 

Diagnostic Information and Procedures

Fuel System Diagnosis

B947H11704001

Condition

Possible cause

Correction / Reference Item

Engine will not start or is 
hard to start (No fuel 
reaching the intake 
manifold)

Clogged fuel filter or fuel hose.

Clean or replace.

Defective fuel pump.

Replace.

Defective fuel pressure regulator.

Replace.

Defective fuel injector.

Replace.

Defective fuel pump relay.

Replace.

Defective ECM.

Replace.

Open-circuited wiring connection.

Check and repair.

Engine will not start or is 
hard to start (Incorrect 
fuel/air mixture)

TP sensor out of adjustment.

Adjust.

Defective fuel pump.

Replace.

Defective fuel pressure regulator.

Replace.

Defective TP sensor.

Replace.

Defective CKP sensor.

Replace.

Defective IAP sensor.

Replace.

Defective ECM.

Replace.

Defective ECT sensor.

Replace.

Defective IAT sensors.

Replace.

Defective AP sensors.

Replace.

Clogged ISC valve air passage way.

Repair or replace.

Engine stalls often 
(Incorrect fuel/air mixture)

Defective IAP sensor or circuit.

Repair or replace.

Clogged fuel filter.

Clean or replace.

Defective fuel pump.

Replace.

Defective fuel pressure regulator.

Replace.

Defective ECT sensor.

Replace.

Defective thermostat.

Replace.

Defective IAT sensor.

Replace.

Damaged or cracked vacuum hose.

Replace.

Damaged or cracked ISC valve.

Repair or replace.

Engine stalls often (Fuel 
injector improperly 
operating)

Defective fuel injector.

Replace.

No injection signal from ECM.

Repair or replace.

Open or short circuited wiring 
connection.

Repair or replace.

Defective battery or low battery voltage.

Replace or recharge.

Engine runs poorly in 
high speed range 
(Defective control circuit 
or sensor)

Low fuel pressure.

Repair or replace.

Defective TP sensor.

Replace.

Defective IAT sensor.

Replace.

Defective CMP sensor.

Replace.

Defective CKP sensor.

Replace.

Defective GP switch.

Replace.

Defective IAP sensor.

Replace.

Defective ECM.

Replace.

TP sensor out of adjustment.

Replace.

Defective STP sensor and/or STVA.

Replace.

Fuel System:  1G-5

Repair Instructions

Fuel Pressure Inspection

B947H11706001

WARNING

!

 

• Keep away from fire or spark.

• Spilled gasoline should be wiped off 

immediately.

• Work in a well-ventilated area.

 

Inspect the fuel pressure in the following procedures:

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

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

2) Place a rag under the fuel feed hose (1) and remove 

the fuel feed hose.

3) Install the special tools between the fuel pump and 

fuel delivery pipe.

Special tool

(A):  09940–40211 (Fuel pressure gauge 

adapter)

(B):  09940–40220 (Fuel pressure gauge 

attachment)

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

kPa))

(D):  09915–74521 (Adapter hose)

4) Turn the ignition ON and check for fuel pressure.

Fuel pressure
Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

If the fuel pressure is lower than the specification, 
check for the followings:

• Fuel hose leakage

• Clogged fuel filter

• Pressure regulator

• Fuel pump
If the fuel pressure is higher than the specification, 
check for the followings:

• Fuel pump

• Pressure regulator

5) Remove the special tools.

WARNING

!

 

Before removing the special tools, turn the 
ignition switch OFF and release the fuel 
pressure slowly.

 

6) Reinstall the fuel tank. Refer to “Fuel Tank Removal 

and Installation” (Page 1G-9).

NOTE

Connect the fuel feed hose to the fuel pump 
until it locks securely (a click is heard).

 

1

I947H1170001-01

(A)

(C)

(D)

(B)

I947H1170021-01

1G-6 Fuel System: 

Fuel Pump Inspection

B947H11706002

Turn the ignition switch ON and check that the fuel pump 
operates for a few seconds.
If the fuel pump motor does not make operating sound, 
inspect the fuel pump circuit connections or inspect the 
fuel pump relay and TO sensor. Refer to “Fuel Pump 
Relay Inspection” (Page 1G-7) and “DTC “C23” (P1651-
H/L): TO Sensor Circuit Malfunction” in Section 1A 
(Page 1A-68).
If the fuel pump relay, TO sensor and fuel pump circuit 
connections are OK, the fuel pump may be faulty, 
replace the fuel pump with a new one. Refer to “Fuel 
Pump Disassembly and Assembly” (Page 1G-11).

Fuel Discharge Amount Inspection

B947H11706003

WARNING

!

 

• Keep away from fire or spark.

• Spilled gasoline should be wiped off 

immediately.

• Work in a well-ventilated area.

 

Inspect the fuel discharge amount in the following 
procedures:

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

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

2) Place a rag under the fuel feed hose (1) and 

disconnect fuel feed hose from the fuel pump.

3) Connect a proper fuel hose (2) to the fuel pump.

4) Place the measuring cylinder and insert the fuel 

hose end into the measuring cylinder.

5) Disconnect the fuel pump lead wire coupler (3).

6) Connect a proper lead wire into the fuel pump lead 

wire coupler (fuel pump side) and apply 12 V to the 
fuel pump (between (+) Y/R wire and (–) B/W wire) 
for 10 seconds and measure the amount of fuel 
discharged.
If the discharge amount is out of the specification, 
the probable cause may be failure of the fuel pump 
or clogged fuel filter.

NOTE

The battery must be in fully charged 
condition.

 

Fuel discharge amount
222 ml (7.5/7.8 US/lmp oz) and more/10 seconds

7) After finishing the fuel discharge inspection, reinstall 

the fuel tank. Refer to “Fuel Tank Removal and 
Installation” (Page 1G-9).

NOTE

Connect the fuel feed hose to the fuel pump 
until it locks securely (a click is heard).

 

1

I947H1170002-01

2

3

I947H1170022-01

I947H1170023-01

Fuel System:  1G-7

Fuel Pump Relay Inspection

B947H11706004

Refer to “Electrical Components Location” in Section 0A 
(Page 0A-7).
Inspect the fuel pump 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 fuel pump relay (1).

3) First, check for insulation with the tester between 

terminals “A” and “B”. Next, check for continuity 
between “A” and “B” with 12 V voltage applied, 
positive (+) to terminal “C” and negative (–) to 
terminal “D”. If continuity does not exist, replace the 
relay with a new one.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity test (

)

Fuel Hose Inspection

B947H11706005

Refer to “Fuel Line Inspection” in Section 0B (Page 0B-
10).

Fuel Level Gauge Inspection

B947H11706006

Refer to “Fuel Level Gauge Inspection” in Section 9C 
(Page 9C-5).

1

I947H1170024-01

“A”

“B”

“C”

“D”

I718H1170013-01

1G-8 Fuel System: 

Fuel Tank Construction

B947H11706007

1

4

2

3

4

4

“B”

“B”

“B”

“A”

I947H1170025-02

1. Fuel tank heat shield

: Aluminum film side should face the engine side.

3. Fuel tank front bracket

“A”: Insert to the bracket.

2. Fuel tank front cover

4. Velcro fastenings

: Clean the adhesive surface before adhering 
the velcro fastenings.

“B”: Apply adhesive agent.

Fuel System:  1G-9

Fuel Tank Removal and Installation

B947H11706008

Removal

WARNING

!

 

• Keep away from fire or spark.

• Spilled gasoline should be wiped off 

immediately.

• Work in a well-ventilated area.

 

1) Remove the front seat. Refer to “Exterior Parts 

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

2) Take out the fuel tank prop stay (1).

3) Remove the bolts.

4) Lift and support the fuel tank with the prop stay.

5) Disconnect the fuel pump lead wire coupler (2).

6) Place a rag under the fuel feed hose (3) and 

disconnect the fuel feed hose from the fuel tank.

CAUTION

!

 

When removing the fuel tank, do not leave 
the fuel feed hose on the fuel pump side.

 

7) Disconnect the fuel tank drain hose (4).

8) Disconnect the surge hose (5). (For E-33)

9) Disconnect the fuel tank breather hose. (Except for 

E-33)

10) Remove the fuel tank by removing its bracket bolt 

(6).

Installation

Install the fuel tank in the reverse order of removal.
Pay attention to the following point:

NOTE

Connect the fuel feed hose to the fuel pump 
until it locks securely (a click is heard).

 

1

I947H1170026-01

I947H1170003-02

I947H1170027-01

2

3

5

4

I947H1170028-01

6

I947H1170029-01

1G-10 Fuel System: 

Fuel Pump Components

B947H11706009

1

2

3

5

6

7

4

3

3

3

(a)

FWD

FWD

I947H1170030-02

1. Fuel level gauge

4. Joint

7. Fuel mesh filter

: Apply grease.

2. Fuel pressure regulator assembly

5. Fuel pump

: 10 N

⋅

m (1.0 kgf-m, 7.0 lbf-ft)

: Do not reuse.

3. O-ring

6. Fuel pump case

: Apply engine oil.

Fuel System:  1G-11

Fuel Pump Disassembly and Assembly

B947H11706010

Disassembly

1) Remove the fuel tank. Refer to “Fuel Tank Removal 

and Installation” (Page 1G-9).

2) Remove the fuel pump assembly (1) by removing its 

mounting bolts diagonally.

WARNING

!

 

• Spilled gasoline should be wipe off 

immediately.

• Keep away from fire or spark.

• Work in a well-ventilated area.

 

3) Disconnect the lead wires (2).

4) Remove the fuel level gauge (3).

5) Remove the fuel pressure regulator assembly (4).

CAUTION

!

 

Never remove the fuel pressure regulator (5) 
from the holder.

 

6) Remove the O-ring (6) and fuel pump case (7).

7) Remove the O-ring (8) and joint (9).

8) Remove the O-ring (10) and lead wires (11).

1

I947H1170004-01

2

I947H1170005-01

3

I947H1170006-01

4

I947H1170007-01

5

I947H1170008-01

6

7

I947H1170009-01

8

9

11

10

I947H1170010-01

1G-12 Fuel System: 

9) Remove the fuel mesh filter (12).

10) Remove the fuel pump (13).

Assembly

Refer to “Fuel Mesh Filter Inspection and Cleaning” 
(Page 1G-13).
Assemble the fuel tank pump in the reverse order of the 
disassembly. Pay attention to the following points:

CAUTION

!

 

• To prevent fuel leakage, the bushing and 

O-ring must be replaced with new ones.

• Apply engine oil lightly to the O-rings.

 

CAUTION

!

 

Connect all lead wires securely so as not to 
cause contact failure.

 

• Install a new O-ring and apply grease to it.

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

WARNING

!

 

The O-ring must be replaced with a new one 
to prevent fuel leakage.

 

12

13

I947H1170011-01

I947H1170012-01

I947H1170013-01

1. Fuel pump (+) lead wire (Y/R)

2. Fuel level gauge (+) lead wire (R/B)

3. Fuel pump (–) lead wire (B/W)

4. Fuel level gauge (–) lead wire (B/W)

1

2

3

4

I947H1170014-01

2

3

4

I947H1170018-01

I947H1170015-01

Fuel System:  1G-13

• When installing the fuel pump assembly, first tighten 

all the fuel pump mounting bolts lightly and then to the 
specified torque in the ascending of numbers.

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

Fuel Mesh Filter Inspection and Cleaning

B947H11706011

Inspect the fuel mesh filter in the following procedures:

1) Remove the fuel mesh filter. Refer to “Fuel Pump 

Disassembly and Assembly” (Page 1G-11).

2) If the fuel mesh filter is clogged with foreign particles, 

it hinders smooth gasoline flow resulting in loss of 
engine power. Such a filter should be cleaned by 
blowing with compressed air.

NOTE

When the fuel mesh filter is dirtied 
excessively, replace the fuel filter cartridge 
with a new one.

 

3) After finishing the fuel mesh filter inspection, reinstall 

the fuel mesh filter. Refer to “Fuel Pump 
Disassembly and Assembly” (Page 1G-11).

Fuel Injector / Fuel Delivery Pipe / T-joint 
Removal and Installation

B947H11706012

Refer to “Throttle Body Disassembly and Assembly” in 
Section 1D (Page 1D-11).

Fuel Injector Inspection and Cleaning

B947H11706013

Inspect the fuel injector in the following procedures:

1) Remove the fuel injector. Refer to “Throttle Body 

Disassembly and Assembly” in Section 1D 
(Page 1D-11).

2) Check the fuel injector for evidence of dirt and 

contamination. If present, clean and check for 
presence of dirt in the fuel lines and fuel tank.

3) Install the fuel injector. Refer to “Throttle Body 

Disassembly and Assembly” in Section 1D 
(Page 1D-11).

(1) (6)

(2)

(3)

(4)

(5)

(a)

I947H1170016-01

I947H1170017-01

I947H1170031-01

1G-14 Fuel System: 

Specifications

Service Data

B947H11707001

Injector + Fuel Pump + Fuel Pressure Regulator

Fuel

Tightening Torque Specifications

B947H11707002

NOTE

The specified tightening torque is described in the following.
“Fuel Pump Components” (Page 1G-10)

 

Reference:

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

Item

Specification

Note

Injector resistance

11 – 13 

Ω

 at 20 

°

C (68 

°

F)

Fuel pump discharge amount

222 ml (7.5/7.8 US/lmp oz) and more/10 sec.

Fuel pressure regulator operating 
set pressure

Approx. 300 kPa (3.0 kgf/cm

2

, 43 psi)

Item

Specification

Note

Fuel type

Use only unleaded gasoline of at least 90 pump octane (R/2 
+ M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less 
than 10% ethanol, or less than 5% methanol with 
appropriate cosolvents and corrosion inhibitor is permissible.

E-03, 14, 28, 33

Gasoline used should be graded 95 octane (Research 
Method) or higher. Unleaded gasoline is recommended.

E-02, 19, 24, 51

Fuel tank capacity

Including 

reserve

16.5 L (4.4/3.6 US/lmp gal)

E-33

17.5 L (4.6/3.8 US/lmp gal)

Others

Fuel level 

indicator light 

lighting

Approx. 3.5 L (0.9/0.8 US/lmp gal)

Fastening part

Tightening torque

Note

N

⋅

m

kgf-m

lbf-ft

Fuel pump mounting bolt

10

1.0 

7.0 

)

(Page 1G-13)

Fuel System:  1G-15

Special Tools and Equipment

Recommended Service Material

B947H11708001

NOTE

Required service material is also described in the following.
“Fuel Pump Components” (Page 1G-10)

 

Special Tool

B947H11708002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or 
equivalent

P/No.: 99000–25010

)

(Page 1G-12)

09900–25008

09915–74521

Multi circuit tester set

Adapter hose

)

(Page 1G-7)

)

(Page 1G-5)

09915–77331

09940–40211

Oil pressure gauge (1000 
kPa)

Fuel pressure gauge 
adapter

)

(Page 1G-5)

)

(Page 1G-5)

09940–40220
Fuel pressure gauge 
attachment

)

(Page 1G-5)