Suzuki GSX-R1000. Service Manual - part 38

9A-9 Wiring Systems: 

1

2

3

5

6

7

8

“C”

“D”

“E”

4

4

“A”

“B”

Upside

I947H1910909-03

1. Steel clamp

: Set the clamp facing downward and bend it to outside.

8. Clamp

: Put the coupler in the frame rib and face the clamp end inside.

2. Clamp

: Bind the wiring harness and battery negative lead wires at blue 
taping point and face the clamp end outside and downward. Be 
sure not to slacken the rear brake light switch lead wire.

“A”: Be sure not to pinch the CKP sensor lead wire between engine 

and water hose.

3. Clamp

: Bind the wiring harness and starter motor lead wire at blue taping 
point and cut off the excess tip of the clamp.

“B”: Put the coupler between the rear turn signal and frame cover.

4. ECM cushion

“C”: Do not twist the wiring harness.

5. FP relay

“D”: Bring the part number sticker on the wiring harness upward.

Do not twist the wiring harness.

6. Turn signal/side-stand relay

“E”: Put the turn signal/side-stand relay lead wires inside the frame.

7. Cooling fan relay

Wiring Systems:  9A-10

“ a ”

“ a ”

“ a ”

“ b ”

“ c ”

“ d ”

(f)

3

2

1

6

7

8

4

4

“A”

FWD

FWD

FWD

FWD

FWD

(d)

5

(a)

(a)

(b)

(c)

(h)

(f)

(e)

(g)

I947H1910910-02

1. Cylinder head cover

“A”: Pass the oil pressure switch lead wire between cylinder and 

generator lead wires.

: 14  N

⋅

m (1.4 kgf-m, 10.0 lbf-ft)

2. CMP sensor

“a”: 90

°

: 145 N

⋅

m (14.5 kgf-m, 105.0 lbf-ft)

3. Battery negative lead wire

“b”: 45

°

: 6.5  N

⋅

m (0.65 kgf-m, 4.5 lbf-ft)

4. Starter motor lead wire

“c”: 30

°

: 11  N

⋅

m (1.1 kgf-m, 8.0 lbf-ft)

5. Oil pressure switch

“d”: 15

°

: 5.5  N

⋅

m (0.55 kgf-m, 4.0 lbf-ft)

6. GP switch

: 10 N

⋅

m (1.0 kgf-m, 7.0 lbf-ft)

: Apply bond.

7. CKP sensor

: 4 N

⋅

m (0.4 kgf-m, 3.0 lbf-ft)

8. Speed sensor

: 1.5 N

⋅

m (0.15 kgf-m, 1.0 lbf-ft)

9A-11 Wiring Systems: 

Specifications

Service Data

B947H1910S001

Electrical

Tightening Torque Specifications

B947H1910S002

NOTE

The specified tightening torque is described in the following.
“Wiring Harness Routing Diagram” (Page 9A-7)

 

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

B947H1910T001

NOTE

Required service material is also described in the following.
“Wiring Harness Routing Diagram” (Page 9A-7)

 

Item

Specification

Note

Fuse size

Headlight

HI

10 A

LO

10 A

Ignition

15 A

Signal

10 A

Fuel

10 A

Fan

15 A

Main

30 A

Lighting Systems:  9B-1

Body and Accessories

Lighting Systems

Repair Instructions

Headlight Components

B947H19206001

Headlight Removal and Installation

B947H19206002

Removal

1) Remove the body cowling assembly. Refer to 

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

2) Remove the air intake pipes (1). Refer to “Exterior 

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

3) Remove the wiring harness No. 2 (2) by 

disconnecting the couplers and clamps.

1

2

3

FWD

FWD

I947H1920001-02

1. Headlight Low beam bulb (12 V 55 W, H11)

2. Headlight High beam bulb (12 V 65 W, H9)

3. Position light bulb (12 V 5 W) x 2

1

2

I947H1920002-01

9B-2 Lighting Systems: 

4) Remove the intake pipe covers (3).

5) Remove the intake cover (4).

6) Remove the body cowling (5).

Installation

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

• Route the wiring harness properly. Refer to “Wiring 

Harness Routing Diagram” in Section 9A (Page 9A-7).

• After installing, be sure to inspect the headlight beam. 

Refer to “Headlight Beam Adjustment” (Page 9B-3).

Headlight Bulb and Position Light Bulb 
Replacement

B947H19206003

CAUTION

!

 

When you touch the bulb with your bare 
hands, clean the bulb with a cloth moistened 
with alcohol or soap water to prevent 
premature bulb failure.

 

Low Beam Bulb

1) Remove the combination meter. Refer to 

“Combination Meter Removal and Installation” in 
Section 9C (Page 9C-2).

2) Disconnect the headlight (Low beam) coupler (1).

3) Remove the headlight bulb/socket (Low beam) (2) 

by turning it counterclockwise.

4) Replace the headlight bulb (Low beam) with a new 

one.

5) Reinstall the removed parts.

High Beam Bulb

1) Remove the body cowling cover. Refer to “Exterior 

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

2) Disconnect the headlight (High beam) coupler (1).

3) Remove the headlight bulb/socket (High beam) (2) 

by turning it counterclockwise.

4) Replace the headlight bulb (High beam) with a new 

one.

5) Reinstall the removed parts.

“A”: Velcro fastening

3

I947H1920003-01

5

4

I947H1920005-01

“A”

I947H1920006-01

1

2

I947H1920007-01

1

2

I947H1920008-01

Lighting Systems:  9B-3

Position Light Bulb

1) Disconnect the position light socket (1).

2) Replace the position light bulb (2) with a new one.

3) Reinstall the position light socket.

Headlight Beam Adjustment

B947H19206004

Adjust the headlight beam, both horizontally and 
vertically.

NOTE

• To adjust the headlight beam, adjust the 

beam horizontally first, then vertically.

• It is not necessary to remove the 

combination meter to turn the adjusters.

 

Front Turn Signal Light Components

B947H19206005

1

I947H1920009-01

2

I947H1920010-01

“A”: Horizontal adjuster

“B”: Vertical adjuster

“A”

“B”

I947H1920011-02

FWD

FWD

1

2

3

I947H1920012-01

1. Turn signal light bulb (12 V 21 W)

2. Front turn signal light

3. Socket

9B-4 Lighting Systems: 

Front Turn Signal Light Removal and 
Installation

B947H19206006

Removal

1) Remove the screw.

2) Disconnect the front turn signal coupler (1).

3) Remove the turn signal light assembly (2).

Installation

Install the front turn signal light in the reverse order of 
removal.

Front Turn Signal Light Bulb Replacement

B947H19206007

CAUTION

!

 

When you touch the bulb with your bare 
hands, clean the bulb with a cloth moistened 
with alcohol or soap water to prevent 
premature bulb failure.

 

1) Remove the turn signal light assembly.

2) Remove the socket (1) by turning it 

counterclockwise.

3) Replace the front turn signal light bulb (2).

I947H1920013-01

1

2

I947H1920014-01

1

I947H1920015-01

2

I947H1920016-01

Lighting Systems:  9B-5

Rear Lighting System Construction

B947H19206008

(b)

1

2

2

3

5

4

(a)

(c)

I947H1920017-01

1. License plate light assembly

4. Rear combination light

: 1.8 N

⋅

m (0.18 kgf-m, 1.5 lbf-ft)

2. Reflex reflector (E-03, 28, 33 only)

5. Rear turn signal light assembly (LH/RH)

: 2.8 N

⋅

m (0.28 kgf-m, 2.0 lbf-ft)

3. Clamp

: Clamp the license plate light lead wire 
so as not to be slack.

: 5  N

⋅

m (0.5 kgf-m, 3.5 lbf-ft)

: Apply thread lock to thread part.

9B-6 Lighting Systems: 

Rear Combination Light Removal and 
Installation

B947H19206009

Removal

1) Remove the frame cover assembly. Refer to 

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

2) Remove the clamps (1).

3) Disconnect the combination light coupler (2).

4) Remove the rear combination light assembly (3).

5) Remove the combination light bracket (4).

Installation

Install the rear combination light in the reverse order of 
removal. Pay attention to the following point:

• Tighten the combination light mounting bolts (1) to the 

specified torque. 

NOTE

When reusing the removed bolts (1), apply a 
small quantity of the thread lock to them.

 

Tightening torque
Rear combination light mounting bolt (a):  2.8 N·m 
(0.28 kgf-m, 2.0 lbf-ft)

:  Thread lock cement 99000–32110 

(THREAD LOCK CEMENT SUPER “1322” or 
equivalent)

Rear Combination Light Replacement

B947H19206010

CAUTION

!

 

If LED operation is abnormal, replace the rear 
combination light with a new one.

 

1

2

3

I947H1920018-01

4

I947H1920019-01

(a)

1

I947H1920020-01

Lighting Systems:  9B-7

License Plate Light Components

B947H19206011

License Plate Light Removal and Installation

B947H19206012

Removal

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

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

2) Disconnect the license plate light coupler (1).

3) Remove the nuts.

4) Remove the license plate light assembly (2).

1

2

3

(a)

I947H1920021-01

1. License plate light bulb (12 V 5 W)

3. Lens

2. Lens cover

: 5 N

⋅

m (0.5 kgf-m, 3.5 lbf-ft)

1

I947H1920022-01

I947H1920023-01

2

I947H1920024-01

9B-8 Lighting Systems: 

Installation

Install the license plate light in the reverse order of 
removal. Pay attention to the following point:

• Tighten the license plate light mounting nuts (1) to the 

specified torque.

Tightening torque
License plate light mounting nut (a):  5 N·m (0.5 
kgf-m, 3.5 lbf-ft)

License Plate Light Bulb Replacement

B947H19206013

CAUTION

!

 

When you touch the bulb with your bare 
hands, clean the bulb with a cloth moistened 
with alcohol or soap water to prevent 
premature bulb failure.

 

1) Remove the license plate light mounting nuts.

2) Remove the lens cover (1) by removing the screws.

3) Replace the bulb (2) with a new one.

4) Reinstall the removed parts.

5) Tighten the license plate light mounting nuts (3) to 

the specified torque.

Tightening torque
License plate light mounting nut (a):  5 N·m (0.5 
kgf-m, 3.5 lbf-ft)

(a)

1

I947H1920025-01

I947H1920026-01

1

I947H1920027-01

2

I947H1920028-01

(a)

3

I947H1920029-01

Lighting Systems:  9B-9

Rear Turn Signal Light Components

B947H19206014

Rear Turn Signal Light Removal and Installation

B947H19206015

Removal

1) Remove the frame cover assembly. Refer to 

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

2) Remove the rear combination light. Refer to “Rear 

Combination Light Removal and Installation” 
(Page 9B-6).

3) Disconnect the lead wire coupler (1).

(LH: White, RH: Black)

4) Remove the screws (2).

5) Remove the side frame cover (3) from the center 

frame cover (4). Refer to “Frame Cover 
Construction” in Section 9D (Page 9D-3).

1

2

3

I947H1920030-01

1. Rear turn signal light lens

2. Rear turn signal light bulb (12 V 21 W)

3. Socket

1

2

I947H1920031-01

“A”: Bushing

3

4

“A”

I947H1920032-01

9B-10 Lighting Systems: 

6) Remove the rear turn signal light (5).

Installation

Install the rear turn signal light in the reverse order of 
removal.

Rear Turn Signal Light Bulb Replacement

B947H19206016

CAUTION

!

 

When you touch the bulb with your bare 
hands, clean the bulb with a cloth moistened 
with alcohol or soap water to prevent 
premature bulb failure.

 

1) Remove the rear turn signal light lens (1).

2) Replace the bulb (2).

3) Reinstall the removed parts.

Reflex Reflector Construction

B947H19206017

5

I947H1920033-02

1

I947H1920034-01

2

I947H1920035-01

1

2

2

(a)

I947H1920036-01

1. Front reflex reflector x 2 pcs. (For E-03, 24, 28, 33)

2. Rear reflex reflector x 2 pcs. (For E-03, 28, 33)

: 1.8 N

⋅

m (0.18 kgf-m, 1.5 lbf-ft)

Lighting Systems:  9B-11

Turn Signal / Side-Stand Relay Inspection

B947H19206019

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

NOTE

Make sure that the battery is fully charged.

 

Before removing the turn signal/side-stand relay, check 
the operation of the turn signal light.
If the turn signal light does not illuminate, inspect the 
bulb, turn signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are 
OK, the turn signal relay may be faulty; therefore, 
replace the turn signal/side-stand relay with a new one. 
Refer to “Turn Signal / Side-Stand Relay Removal and 
Installation” (Page 9B-11).

Turn Signal / Side-Stand Relay Removal and 
Installation

B947H19206020

Removal

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

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

2) Remove the turn signal/side-stand relay (1).

Installation

Install the turn signal/side-stand relay in the reverse 
order of removal.

Hazard Switch Inspection

B947H19206021

Inspect the hazard switch in the following procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner 

Box Removal and Installation” in Section 1D 
(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1). 

(Yellow)

3) Inspect the hazard switch for continuity with the 

tester.
If any abnormality is found, replace the left 
handlebar switch assembly with a new one. Refer to 
“Handlebar Removal and Installation” in Section 6B 
(Page 6B-2).

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity (

)

4) After finishing the hazard switch inspection, reinstall 

the removed parts.

1

I947H1920037-02

1

I947H1920038-01

Color

B/R

Bl

Dg

OFF

ON

Position

I947H1920039-01

9B-12 Lighting Systems: 

Turn Signal Switch Inspection

B947H19206022

Inspect the turn signal switch in the following 
procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner 

Box Removal and Installation” in Section 1D 
(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1). 

(Yellow)

3) Inspect the turn signal switch for continuity with the 

tester. If any abnormality is found, replace the left 
handlebar switch assembly with a new one.
Refer to “Handlebar Removal and Installation” in 
Section 6B (Page 6B-2).

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity (

)

4) After finishing the turn signal switch inspection, 

reinstall the removed parts.

Dimmer / Passing Light Switch Inspection

B947H19206023

Inspect the dimmer/passing light switch in the following 
procedures:

1) Remove the air cleaner box. Refer to “Air Cleaner 

Box Removal and Installation” in Section 1D 
(Page 1D-7).

2) Disconnect the left handlebar switch coupler (1). 

(Yellow)

3) Inspect the dimmer/passing light switch for continuity 

with the tester.
If any abnormality is found, replace the left 
handlebar switch assembly with a new one.
Refer to “Handlebar Removal and Installation” in 
Section 6B (Page 6B-2).

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity (

)

4) After finishing the passing light switch inspection, 

reinstall the removed parts.

1

I947H1920040-02

L

PUSH

R

B

Lbl

Lg

Color

Position

I947H1920041-01

1

I947H1920042-02

Position

Color

Y

O

W

HI

LO

PASS

I947H1920043-01

Lighting Systems:  9B-13

Specifications

Service Data

B947H19207001

Wattage

Unit: W

Tightening Torque Specifications

B947H19207002

NOTE

The specified tightening torque is described in the following.
“Rear Lighting System Construction” (Page 9B-5)
“License Plate Light Components” (Page 9B-7)
“Reflex Reflector Construction” (Page 9B-10)

 

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

B947H19208001

NOTE

Required service material is also described in the following.
“Rear Lighting System Construction” (Page 9B-5)

 

Special Tool

B947H19208002

Item

Specification

Headlight

HI

65

LO

55

Position light

5 x 2

Brake light/Taillight

LED

Turn signal light

21 x 4

License plate light

5

Fastening part

Tightening torque

Note

N

⋅

m

kgf-m

lbf-ft

Rear combination light mounting bolt

2.8

0.28 

2.0 

)

(Page 9B-6)

License plate light mounting nut

5

0.5 3.5 

)

(Page 9B-8) / 

)

(Page 9B-8)

Material

SUZUKI recommended product or Specification

Note

Thread lock cement

THREAD LOCK CEMENT SUPER 
“1322” or equivalent

P/No.: 99000–32110

)

(Page 9B-6)

09900–25008
Multi circuit tester set

)

(Page 9B-11) / 

)

(Page 9B-12) / 

)

(Page 9B-12)