Suzuki GSX-R1000 User manual

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No. 1298 GSX-R1000 S/M 99500-39380-01E For PS printing 2009.3.3 (Back: 23 mm) 5/0 DIC255
GSX-R1000
Printed in Japan
K9
K9
GSX-R1000
SERVICE MANUAL
SERVICE MANUAL
99500-39380-01E

FOREWORD
This manual contains an introductory description on the SUZUKI GSX-R1000 and procedures for its inspection/
service and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. 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 better so that you can assure your customers of fast and reliable
service.
© C O PYRIG H T SUZUKI MOTO R C O RP O RATIO N 2009
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content of this manual and the
actual motorcycle.
* 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 motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
!
Inexperienced mechanics or mechanics without the proper toolsand equipment may not be ableto
properlyperform the services described inthismanual.
Improper repairmay result ininjury tothe mechanicand may render the motorcycleunsafefor the
rider and passenger.

00
0
1
2
3
4
5
6
7
8
9
10
11
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication.................................0B-1
Service Data...........................................................0C-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ...........1A-1
Emission Control Devices ...................................... 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension....................................................2C-1
Wheels and Tires ...................................................2D-1
Driveline / Axle ........................................................... 3-i
Precautions .............................................................. 3-1
Drive Chain / Drive Train / Drive Shaft ................... 3A-1
Brake ........................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis ....................4A-1
Front Brakes........................................................... 4B-1
Rear Brakes ...........................................................4C-1
Transmission / Transaxle .......................................... 5-i
Precautions .............................................................. 5-1
Manual Transmission ............................................. 5B-1
Clutch .....................................................................5C-1
Steering....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering / Handlebar .............................................. 6B-1
Body and Accessories............................................... 9-i
Precautions .............................................................. 9-1
Wiring Systems ...................................................... 9A-1
Lighting Systems.................................................... 9B-1
Combination Meter / Fuel Meter / Horn..................9C-1
Exterior Parts .........................................................9D-1
Body Structure ....................................................... 9E-1
TABLE OF CONTENTS

Table of Contents 00- i
00
Section 00
CONTENTS
Precautions
Precautions ...............................................00-1
Precautions........................................................... 00-1
Warning / Caution / Note..................................... 00-1
General Precautions ........................................... 00-1
Precautions for Electrical Circuit Service ............ 00-2

00-1 Precautions:
Precautions
Precautions
Precautions
Warning / Caution / Note
B947H10000001
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 messages
highlighted by these signal words.
WARNING
!
Indicates a potential hazard that could result
in death or injury.
CAUTION
!
Indicates a potential hazard that could result
in motorcycle damage.
NOTE
Indicates special information to make
maintenance easier or 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
WARNINGS 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
B947H10000002
WARNING
!
• Proper service and repair procedures are
important for the safety of the service
mechanic and the safety and reliability of
the motorcycle.
•When2ormorepersonsworktogether,
pay attention to the safety of each other.
•Whenitisnecessarytoruntheengine
indoors, make sure that exhaust gas is
forced outdoors.
• 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.
•Neverusegasolineascleaningsolvent.
•Toavoidgettingburned,donottouchthe
engine, engine oil, radiator and exhaust
system until they have cooled.
•Afterservicingthefuel,oil,water,exhaust
or brake systems, check all lines and
fittings related to the system for leaks.
CAUTION
!
•Ifpartsreplacementisnecessary,replace
the parts with Suzuki Genuine Parts or
their equivalent.
•Whenremovingpartsthataretobereused,
keep them arranged in an orderly manner
so that they may be reinstalled in the
proper order and orientation.
•Besuretousespecialtoolswhen
instructed.
•Makesurethatallpartsusedin
reassembly are clean. Lubricate them
when specified.
•Usethespecifiedlubricant,bondor
sealant.
•Whenremovingthebattery,disconnectthe
negative (–) cable first and then the
positive (+) cable.
•Whenreconnectingthebattery,connect
the positive (+) cable first and then the
negative (–) cable, and replace the terminal
cover on the positive (+) terminal.
• When performing service to electrical
parts, if the service procedures do not
require use of battery power, disconnect
the negative (–) cable the battery.
•Whentighteningthecylinderheadorcase
bolts and nuts, tighten the larger sizes
first. Always tighten the bolts and nuts
diagonally from the inside toward outside
and to the specified tightening torque.
•Wheneveryouremoveoilseals,gaskets,
packing, O-rings, locking washers, self-
locking nuts, cotter pins, circlips and
certain other parts as specified, be sure to
replace them with new ones. Also, before
installing these new parts, be sure to
remove any left over material from the
mating surfaces.

Precautions: 00-2
•Neverreuseacirclip.Wheninstallinga
new circlip, take care not to expand the
end gap larger than required to slip the
circlip over the shaft. After installing a
circlip, always ensure that it is completely
seated in its groove and securely fitted.
•Useatorquewrenchtotightenfasteners
to the specified torque. Wipe off grease
and oil if a thread is smeared with them.
•Afterreassembling,checkpartsfor
tightness and proper operation.
•Toprotecttheenvironment,donot
unlawfully dispose of used motor oil,
engine coolant and other fluids: batteries,
and tires.
•ToprotectEarth’snaturalresources,
properly dispose of used motorcycle and
parts.
Precautions for Electrical Circuit Service
B947H10000003
When handling the electrical parts or servicing FI
system, observe the following points for the safety of the
systems.
Electrical Parts
Connector / Coupler
•FaultyFIsystemisoftenrelatedtopoorelectrical
contact of connector/coupler. Before servicing
individual electronic part, check electrical contact of
the connector/coupler.
•Whenconnectingaconnector,besuretopushitin
until a click is felt.
•Withalocktypecoupler,besuretoreleasethelock
when disconnecting, and push it in fully to engage the
lock when connecting.
•Whendisconnectingthecoupler,besuretoholdthe
coupler body and do not pull the lead wires.
•Inspecteachterminalontheconnector/couplerfor
looseness or bending.
•Pushinthecouplerstraightly.Anangledorskewed
insertion may cause the terminal to be deformed,
possibly resulting in poor electrical contact.
•Inspecteachterminalforcorrosionand
contamination. The terminals must be clean and free
of any foreign material which could impede proper
terminal contact.
•Beforerefittingthesealedcoupler,makesureitsseal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.
•Inspecteachleadwirecircuitforpoorconnectionby
shaking it by hand lightly. If any abnormal condition is
found, repair or replace.
•Whentakingmeasurementsatelectricalconnectors
using a tester probe, be sure to insert the probe from
the wire harness side (rear) of the connector/coupler.
I823H1000002-01
1. Coupler 2. Probe
I310G1000002-01
I310G1000003-02
2
1
I649G1000013-02

00-3 Precautions:
•Whenconnectingmeterprobefromtheterminalside
of the coupler (where connection from harness side
not being possible), use extra care not to force and
cause the male terminal to bend or the female
terminal to open. Connect the probe as shown to
avoid opening of female terminal. Never push in the
probe where male terminal is supposed to fit.
•Checkthemaleconnectorforbendandfemale
connector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust, etc.
•Avoidapplyinggreaseorothersimilarmaterialto
connector/coupler terminals to prevent electric
trouble.
Clamp
•Clampthewireharnessatsuchpositionsasindicated
in “Wiring Harness Routing Diagram” in Section 9A
(Page 9A-7).
•Bendtheclampproperlysothatthewireharnessis
clamped securely.
•Inclampingthewireharness,usecarenottoallowit
to hang down.
•Donotusewireoranyother substitute for the band
type clamp.
Fuse
•Whenafuseisblown,alwaysinvestigatethecauseto
correct it and then replace the fuse.
•Donotuseafuseofdifferentcapacity.
•Donotusewireoranyothersubstituteforthefuse.
Switch
Never apply grease material to switch contact points to
prevent damage.
ECM / Various sensors
•Sinceeachcomponentisahigh-precisionpart,great
care should be taken not to apply any severe impacts
during removal and installation.
•Becarefulnottotouch the electrical terminals of the
electronic parts (ECM, etc.). The static electricity from
your body may damage them.
3. Coupler 4. Probe “A”: Where male terminal fits
3
4
4
“A”
I649G1000030-02
C O R R E C T IN C O RR E CT
I718H1000001-02
I649G1000001-02
I310G1000007-01
I310G1000008-01

Precautions: 00-4
•Whendisconnectingandconnectingthecoupler,
make sure to turn OFF the ignition switch, or
electronic parts may get damaged.
Battery
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the FI system instantly when reverse
power is applied.
• Removing any battery terminal of a running engine is
strictly prohibited. The moment such removal is made,
damaging counter electromotive force will be applied
to the electronic unit which may result in serious
damage.
•Beforemeasuringvoltageateachterminal,checkto
make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis.
•Neverconnectanytester(voltmeter,ohmmeter,or
whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit
may result.
•Neverconnectanohmmetertotheelectronicunitwith
its coupler connected. If attempted, damage to ECM
or sensors may result.
•Besuretouseaspecifiedvoltmeter/ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
Electrical Circuit Inspection Procedure
While there are various methods for electrical circuit
inspection, described here is a general method to check
for open and short circuit using an ohmmeter and a
voltmeter.
Open circuit check
Possible causes for the open circuit are as follows. As
the cause can exist in the connector/coupler or terminal,
they need to be checked carefully.
•Looseconnectionofconnector/coupler.
•Poorcontactofterminal(duetodirt,corrosionorrust,
poor contact tension, entry of foreign object etc.).
•Wireharnessbeingopen.
•Poorterminal-to-wireconnection.
When checking system circuits including an electronic
control unit such as ECM, etc., it is important to perform
careful check, starting with items which are easier to
check.
1) Disconnect the negative (–) cable from the battery.
1. Ignition switch
1
I837H1000001-01
I718H1000004-01
I310G1000011-01
I310G1000012-02

00-5 Precautions:
2) Check each connector/coupler at both ends of the
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped.
3) Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact
(possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact to
increase tension or replace. The terminals must be
clean and free of any foreign material which could
impede proper terminal contact.
4) Using continuity inspect or voltage check procedure
as described below, inspect the wire harness
terminals for open circuit and poor connection.
Locate abnormality, if any.
Continuity check
1) Measure resistance across coupler “B” (between “A”
and “C” in figure).
If no continuity is indicated (infinity or over limit), the
circuit is open between terminals “A” and “C”.
2) Disconnect the coupler “B” and measure resistance
between couplers “A” and “B-1”.
If no continuity is indicated, the circuit is open
between couplers “A” and “B-1”. If continuity is
indicated, there is an open circuit between couplers
“B-2” and “C” or an abnormality in coupler “B-2” or
coupler “C”.
Voltage check
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors/couplers connected and voltage
applied to the circuit being checked, measure
voltage between each terminal and body ground.
2) If measurements were taken as shown in the figure
and results were listed in the following, it means that
the circuit is open between terminals “A” and “B”.
Voltage between
“A” and body ground: Approx. 5 V
“B” and body ground: Approx. 5 V
“C” and body ground: 0 V
1. Sensor “A”: Check for loose connection
“B”: Check contact tension by inserting and removing
“C”: Check each terminal for bend and proper alignment
“D”: Looseness of crimping
“E”: Open
“F”: Thin wire (A few strands left)
E CM
“A”
1
“A”
I718H1000005-02
“C”
“B”
I649G1000027-02
“D”
“E”
“F”
I649G1000028-02
E CM
“A”
“B”
“C”
I705H1000006-02
E CM
“A”
“B”“C”
“B-2”
“B-1”
I705H1000010-02

Precautions: 00-6
3) Also, if measured values are as listed following, a
resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals “A” and
“B”.
Voltage between
“A” and body ground: Approx. 5 V
“B” and body ground: Approx. 5 V – 2 V voltage
drop
“C” and body ground: 3 V – 2 V voltage drop
Short circuit check (Wire harness to ground)
1) Disconnect the negative (–) cable from the battery.
2) Disconnect the connectors/couplers at both ends of
the circuit to be checked.
NOTE
If the circuit to be checked branches to other
parts as shown, disconnect all connectors/
couplers of those parts. Otherwise, diagnosis
will be wrong.
3) Measure resistance between terminal at one end of
circuit (“A” terminal in figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals “A” and “C”.
5V
5V
5V
0V
E CM
“A”
“B”“C”
“A” “B” “ C”
I705H1000007-01
“D”: To other parts “E”: Other parts
E CM
5V
“A”
“B”
“C”
“D”
“E”
“A” “ C”
I705H1000008-01

00-7 Precautions:
4) Disconnect the connector/coupler included in circuit
(coupler “B”) and measure resistance between
terminal “A” and body ground. If continuity is
indicated, the circuit is shorted to ground between
terminals “A” and “B”.
Using The Multi-Circuit Testers
•UsetheSuzukimulti-circuittesterset.
•Usewell-chargedbatteriesinthetester.
•Besuretosetthetestertothecorrecttestingrange.
Special tool
(A): 09900–25008 (Multi circuit tester set)
Using the testers
•Incorrectlyconnectingthe(+)and(–)probesmay
cause the inside of the tester to be burned.
•Ifthevoltageandcurrentarenotknown,make
measurements using the highest range.
• When measuring the resistance with the multi-circuit
tester (1), ∞will be shown as 10.00 MΩand “1”
flashes in the display.
•Checkthatnovoltageisappliedbeforemakingthe
measurement. If voltage is applied the tester may be
damaged.
• After using the tester, turn the power off.
Special tool
: 09900–25008 (Multi circuit tester set)
NOTE
•Whenconnectingthemulti-circuittester,
use the needle pointed probe to the back
side of the lead wire coupler and connect
the probes of tester to them.
•Usetheneedlepointedprobetoprevent
the rubber of the water proof coupler from
damage.
•Whenusingthemulti-circuittester,donot
strongly touch the terminal of the ECM
coupler with a needle pointed tester probe
to prevent terminal damage.
Special tool
(A): 09900–25009 (Needle-point probe set)
“D”: To other parts
E CM
“A”
“B”“C”
“D”
I705H1000009-02
(A)
I649G1000024-03
I649G1000002-02
(A)
I649G1000025-03

Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description .............................................0A-1
Symbols .............................................................. 0A-1
Abbreviations ...................................................... 0A-1
Vehicle Side View ............................................... 0A-2
Vehicle Identification Number ............................. 0A-3
Fuel and Oil Recommendation ...........................0A-3
Engine Coolant Recommendation ...................... 0A-4
BREAK-IN Procedures........................................ 0A-4
Cylinder Identification.......................................... 0A-4
Country and Area Codes .................................... 0A-5
Wire Color Symbols ............................................0A-5
Warning, Caution and Information Labels
Location ............................................................ 0A-6
Component Location...........................................0A-7
Electrical Components Location ......................... 0A-7
Specifications.......................................................0A-9
Specifications...................................................... 0A-9
Special Tools and Equipment ...........................0A-11
Special Tool ......................................................0A-11
Maintenance and Lubrication................. 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 0B-1
General Description .............................................0B-1
Recommended Fluids and Lubricants................. 0B-1
Scheduled Maintenance ......................................0B-2
Periodic Maintenance Schedule Chart................ 0B-2
Lubrication Points ............................................... 0B-3
Repair Instructions ..............................................0B-3
Air Cleaner Element Replacement...................... 0B-3
Air Cleaner Element Inspection .......................... 0B-3
Exhaust Pipe Bolt and Muffler Bolt Inspection ....0B-4
Exhaust Control Valve Inspection .......................0B-4
Valve Clearance Inspection and Adjustment ......0B-5
Spark Plug Replacement ....................................0B-9
Spark Plug Inspection and Cleaning ...................0B-9
Fuel Line Inspection ..........................................0B-10
Evaporative Emission Control System
Inspection (E-33 only) .....................................0B-10
Engine Oil and Filter Replacement ...................0B-10
Throttle Cable Play Inspection and
Adjustment ......................................................0B-12
PAIR System Inspection ...................................0B-12
Throttle Valve Synchronization .........................0B-12
Cooling System Inspection................................0B-12
Clutch Cable Play Inspection and Adjustment ..0B-14
Drive Chain Inspection and Adjustment ............0B-14
Drive Chain Cleaning and Lubricating...............0B-16
Brake System Inspection ..................................0B-16
Tire Inspection...................................................0B-18
Steering System Inspection ..............................0B-18
Front Fork Inspection ........................................0B-19
Rear Suspension Inspection .............................0B-19
Chassis Bolt and Nut Inspection .......................0B-19
Compression Pressure Check..........................0B-21
Oil Pressure Check ...........................................0B-21
SDS Check........................................................0B-21
Specifications.....................................................0B-21
Tightening Torque Specifications......................0B-21
Special Tools and Equipment ...........................0B-22
Recommended Service Material .......................0B-22
Special Tool ......................................................0B-22
Service Data ............................................. 0C-1
Specifications.......................................................0C-1
Service Data........................................................0C-1
Tightening Torque List ........................................0C-9

0A-1 General Information:
General Information
General Information
General Description
Symbols
B947H10101001
Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.
Abbreviations
B947H10101002
A:
ABDC: 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
B:
BARO: Barometric pressure (Atmospheric pressure)
BBDC: Before Bottom Dead Center
BTDC: Before Top Dead Center
B+: Battery Positive Voltage
C:
CKP Sensor: Crankshaft Position Sensor (CKPS)
CKT: Circuit
CLP Switch: Clutch Lever Position Switch (Clutch
Switch)
CMP Sensor: Camshaft Position Sensor (CMPS)
CO: Carbon Monoxide
CPU: Central Processing Unit
D:
DC: Direct Current
DMC: Dealer Mode Coupler
DOHC: Double Over Head Camshaft
DRL: Daytime Running Light
DTC: Diagnostic Trouble code
Symbol Definition
Tor q u e c o nt r o l re q u ir e d .
Data beside it indicate specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1).
Apply SUZUKI SUPER GREASE “A” or equivalent.
99000-25010
Apply SUZUKI MOLY PASTE or equivalent.
99000-25140
Apply SUZUKI SILICONE GREASE or equivalent.
99000-25100
Apply SUZUKI BOND “1207B” or equivalent.
99000-31140
Apply THREAD LOCK CEMENT SUPER “1303” or equivalent.
99000-32030
Apply THREAD LOCK CEMENT SUPER “1322” or equivalent.
99000-32110
Apply THREAD LOCK CEMENT SUPER “1360” or equivalent.
99000-32130
Use engine coolant or equivalent.
99000-99032-11X
Use fork oil or equivalent.
99000-99001-SS5
Apply MUFFLER SEAL LOCTITE “5920” (commercially available) or equivalent.
Apply or use brake fluid.
Use special tool.
Do not reuse.
Note on reassembly.