GSXR1000 K3 / K4 manual, it's the same as the one above, but it's been through an

460 Pages·2004·19.74 MB·English

FOREWORD GROUP INDEX
Thismanualcontains an introductorydescription on
the SUZUKI GSX-R1000 and procedures for its
inspection/service and overhaul ofits main compo I
GENERAL INFORMATlON
nents.
Other information consideredas generally known is
not included.
I
Read the GENERAL INFORMATION section to PERIODIC MAINTENANCE
familiarize yourselfwith themotorcycle and itsmain
tenance. Use this section as well as othersections
touse as aguide forproperinspection and service. I
ENGINE
This manual will help you know the motorcycle bet
ter so that you can assure your customers of fast
and reliable service.
I
FI SYSTEM DIAGNOSIS
* This manualhas been preparedon the basis
ofthelatest specificationsat the time ofpubli
FUEL SYSTEM AND THROTTLE
cation. Ifmodificationshave been made since
then, differences may exist between the con BODY
tent ofthismanualand theactualmotorcycle.
*Illustrations in this manual are used to show
I
the basic principles of operation and work EXHAUSTSYSTEM
procedures. They may not represent the
actualmotorcycle exactlyin detail.
COOLING AND LUBRICATION
* This manual is written for persons who have
enough knowledge, skills and tools, including SYSTEM
special tools, for servicing SUZUKI motorcy
B
cles. Ifyou do not have theproperknowledge
I
and tools, ask your authorized SUZUKI CHASSIS
motorcycle dealertohelp you. ===================
_ _ _B
~ A WARNING IELECTRICAL SYSTEM
Inexperienced mechanics or mechanics
I without the proper tools and equipment I~-_.
may not be able to properly perform the SERVICING INFORMATlON
servicesdescribedinthis manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle EMISSION CONTROL
unsafefor the riderand passenger. INFORMATION
~----.
I
WIRING DIAGRAM
SUZUKI MOTOR CORPORATION
©COPYRIGHTSUZUKI MOTOR CORPORATION2003
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text ofthis manual isdivided into sections.
2. The section titles are listed inthe GROUP INDEX.
3. Holding the manual as shown atthe right will allow you tofind
the first page ofthe section easily.
\
4. The contents are listed on the first page of each section to \
\,---
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Underthe name of each system or unit, is itsexploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
CD Brakedisc
~ Dustseal
@ Bearing
@ Spacer
@ Spacernut
@ Frontwheel
® Frontaxle
® Brakedisc 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.
e
l!r
Apply oil. Use engine oil unless other-
Use engine coolant.
wise specified.
e
Apply molybdenum oil solution.
lIr
Use 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
A E
ABDC :After Bottom Dead Center ECM : Engine Control Module
AC :Alternating Current Engine Control Unit (ECU)
ACL :Air Cleaner, Air Cleaner Box (FI Control Unit)
API :American Petroleum Institute ECT Sensor : Engine CoolantTemperature
ATDC :After Top Dead Center Sensor (ECTS), WaterTemp.
ATM Pressure: Atmospheric Pressure Sensor (WTS)
:Atmospheric Pressure sensor EVAP : Evaporative Emission
(APS, AP Sensor) EVAP Canister: Evaporative Emission
A/F :Air Fuel Mixture Canister (Canister)
EXC System : Exhaust Control System (EXCS)
B EXC Valve : Exhaust Control Valve (EXCV)
BBDC : Before Bottom Dead Center EXCVActuator: Exhaust Control Valve Actuator
BTDC : Before Top Dead Center (EXCVA)
B+ : Battery Positive Voltage
F
C FI :Fuel Injection, Fuel Injector
CKP Sensor :Crankshaft Position Sensor FP :Fuel Pump
(CKPS) FPR :Fuel Pressure Regulator
CKT :Circuit FP Relay :Fuel Pump Relay
CLP Switch :Clutch Lever Position Switch
G
(Clutch Switch)
CMP Sensor :Camshaft Position Sensor GEN :Generator
(CMPS) GND :Ground
CO :Carbon Monoxide GP Switch :Gear Position Switch
CPU :Central Processing Unit
H
D HC : Hydrocarbons
DC : Direct Current
DMC : Dealer Mode Coupler I
DOHC : Double Over Head Camshaft lAP Sensor :Intake Air Pressure Sensor (lAPS)
DRL : Daytime Running Light IAT Sensor :Intake Air Temperature Sensor
(lATS)
IG :Ignition
L
LCD : Liquid Crystal Display
LED :Light Emitting Diode
(Malfunction Indicator Lamp)
LH :Left Hand
M
MAL-Code :Malfunction Code
(Diagnostic Code)
Max :Maximum
MIL : Malfunction IndicatorLamp
(LED)
Min : Minimum
N
NOX : Nitrogen Oxides
o
OHC :Over Head Camshaft
OPS :Oil Pressure Switch
p
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
SAE :Society of Automotive Engineers
STC System :SecondaryThrottle Control System
(STCS)
STP Sensor :SecondaryThrottle Position Sensor
(STPS)
ST Valve :SecondaryThrottle Valve (STV)
STV Actuator :SecondaryThrottle Valve Actuator
(STVA)
T
TO Sensor :Tip OverSensor (TOS)
TP Sensor :Throttle Position Sensor (TPS)
TPC Valve :Tank Pressure Control Valve (TPCV)
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society ofAutomotive Engineers) J1930 terms and abbreviationswhich may be used in
this manual incompliance 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
DiagnosticTest Mode DTM -
DiagnosticTrouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition EI -
Engine Control Module ECM Engine Control Module (ECM)
FIControl 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
M I
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 SecondaryAir 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 -
SecondaryThrottle 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 : Black with Blue tracer BIBr : Black with Brown tracer
BIG : Black with Green tracer B/Lg : Black with Light green tracer
BIR : Black with Red tracer B/W : Black with White tracer
BN : Black with Yellow tracer BIIB : Blue with Black tracer
BI/G : Blue with Green tracer BIIR : Blue with Red tracer
BI/W : Blue with White tracer BIN : Blue with Yellow tracer
GIB :Green with Black tracer GIBI :Green with Blue tracer
G/W :Green with White tracer GN :Green with Yellow tracer
GrlB :Graywith Black tracer GrlR :Gray with Red tracer
Gr/W :Graywith White tracer GrN :Gray with Yellow tracer
OIB :Orange with Black tracer OIG :Orange with Green tracer
OIR :Orange with Red tracer O/w :Orange with White tracer
ON :Orange with Yellow tracer PIB : Pink with Black tracer
P/w : Pink with White tracer RIB : Red with Black tracer
RIBI : Red with Blue tracer R/W : Red with White tracer
WIB :White with Black tracer WIBI :White with Blue tracer
WIR :White with Red tracer YIB :Yellow with Black tracer
YIBI :Yellow with Blue tracer YIG :Yellow with Green tracer
YIR :Yellow with Red tracer Y/w :Yellow with White tracer
GENERALINFORMATION 1·1
GENERALWFORMATION
I
•
CONTENTS
WARNING/CAUTION/NOTE 1- 2
GENERAL PRECAUTIONS.....................................................................•.....1- 2
SUZUKIGSX-R1000K3 ('03-MODEL) .......................•..................................1- 4
SERIAL NUMBER LOCATION............•.........................................................1- 4
FUEL, OIL AND ENGINE COOLANTRECOMMENDATlON.........••.............1- 5
FUEL (FOR USA ANDCANADA)...................................................•.......1- 5
FUEL (FOR OTHER COUNTRIES)••................•.................................•..•.1- 5
ENGINEOIL (FOR USA)...........................•.............................................1- 5
ENGINE OIL (FOR OTHER COUNTRIES).....................•..•....................1- 5
BRAKEFLUiD•...........................•....................•..................................•....1- 5
FRONTFORKOIL ..........................................•.......................................1- 6
ENGINE COOLANT..........•...........................•.......................•.................1- 6
WATER FOR MIXING ....................•..........................•.............................1- 6
ANTI-FREEZE/ENGINECOOLANT..........•.............................................1- 6
LIQUIDAMOUNTOF WATER/ENGINE COOLANT.........................•....1- 6
BREAK-INPROCEDURES 1- 7
CYLINDERIDENTIFICATION....................................................................•..1- 7
INFORMATIONLABELS...........................................................•...................1- 8
SPECIFICATIONS......................................•..........•.......................•...............1- 9
DIMENSIONSAND DRYMASS 1- 9
ENGINE..........................................••........................................•........•.....1- 9
DRIVE TRAIN...................•.................••.......................•.........•......•...•......1- 9
CHASSiS.................••...................•.•...............•..................•......•.......••.•...1-10
ELECTRICAL.............................................................•.................•..........1-10
CAPACiTIES 1-10
COUNTRYANDAREA CODES....................•................•..............................1-11
1-2 GENERALINFORMATION
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 bythese signal words.
A WARNING
Indicates a potential hazard that could result in death or injury.
ICAUTIONI
Indicates apotential hazard that could result in motorcycle damage.
NOTE:
Indicates specialinformation 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 usegood judgement and basic mechanical safety principles. Ifyou
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS
A WARNING
* Proper service and repair procedures are importantfor 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 ofthe material manufacturer's instructions.
* Never use gasoline as acleaning 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, checkall lines and fittings related
to the system for leaks.