Suzuki GSX-R1000 User manual

FOREWORD GROUP INDEX
COOLING AND LUBRICATION
SYSTEM
FUEL SYSTEM AND THROTTLE
BODY
EMISSION CONTROL
INFORMATION
~----.
B
===================
___ B
~-_.
IPERIODIC MAINTENANCE
IGENERAL INFORMATlON
IFI SYSTEM DIAGNOSIS
IENGINE
IEXHAUSTSYSTEM
ICHASSIS
IELECTRICAL SYSTEM
IWIRING DIAGRAM
ISERVICING INFORMATlON
*This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation.
If modifications have been made since
then, differences
may exist between the con-
tent
of this manual and the actualmotorcycle.
*Illustrations in this manual are used to show
the basic principles
of 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.
If 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 of 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
of fast
and reliable service.
~
I
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.
\\
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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
CD 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
CO
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
FP
FPR
FP Relay
GGEN
GND
GP Switch
HHC
IlAP Sensor
IAT Sensor
IG
LLCD
LED
LH
: 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

M
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
A
Air Cleaner
ACl
Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector
DlC
Dealer Mode Coupler
Diagnostic Test Mode DTM -
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
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)
F
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
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
I
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
MI
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
a
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL -
P
Programmable Read Only Memory PROM -
Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)
Purge Valve Purge Valve Purge Valve (SP Valve)
R
Random Access Memory RAM -
Read Only Memory ROM ROM
S
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)
T
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)
V
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
BN
BI/G
BI/W
GIB
G/W
GrlB
Gr/W
OIB
OIR
ON
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
GN
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
I 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 follow all of 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 related
to the system
for leaks.