2005-2006 GSXR 1000 Service & Repair Manual

99500-39270-01E GSX-R1000

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FI SYSTEM DIAGNOSIS 4 FUEL SYSTEM AND THROTTLE BODY 5 EXHAUST SYSTEM 6 COOLING AND LUBRICATION SYSTEM 7 CHASSIS 8 ELECTRICAL SYSTEM 9 SERVICING INFORMATION 10 EMISSION CONTROL INFORMATION 11 WIRING DIAGRAM 12 FOREWORD 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 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 bet- ter so that you can assure your customers of fast and reliable service.  © COPYRIGHT SUZUKI MOTOR CORPORATION 2005 * 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 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 motorcy- cles. If you do not have the proper knowledge 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. SAMPLE

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. 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 1 Brake disc 2 Collar 3 Dust seal 4 Bearing 5 Spacer 6 Front axle 7 Front wheel A Front axle bolt B Brake disc bolt  ITEM N·m kgf-m lb-ft A 100 10.0 72.5 B 23 2.3 16.5 SAMPLE

SYMBOL 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. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply oil. Use engine oil unless other- wise specified. Use engine coolant. 99000-99032-11X (Except USA) Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Use fork oil. 99000-99044-L01 Apply SUZUKI SUPER GREASE “A”. 99000-25010 (Others) 99000-25030 (USA) Apply or use brake fluid. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in voltage range. Apply SUZUKI BOND “1215”. 99000-31110 (Except USA) Measure in current range. Apply SUZUKI BOND “1207B”. 99104-31140 (USA) Measure in resistance range. Apply SUZUKI BOND “1207B”. 99000-31140 (Except USA) Measure in diode test range. Apply THREAD LOCK SUPER “1303”. 99000-32030 Measure in continuity test range. Apply THREAD LOCK SUPER “1322”. 99000-32110 (Except USA) Use special tool. Apply THREAD LOCK “1342”. 99000-32050 (USA) Indication of service data. SAMPLE

ABBREVIATIONS USED IN THIS MANUAL 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 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 E ECM : 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) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay G GEN : Generator GND : Ground GP Switch : Gear Position Switch H HC : Hydrocarbons I IAP Sensor : Intake Air Pressure Sensor (IAPS) (MAP Sensor) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition L LCD : Liquid Crystal Display LED : Light Emitting Diode (Malfunction Indicator Lamp) LH : Left Hand SAMPLE

M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (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 SDS : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS) ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator (STVA) T TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS) SAMPLE

WIRE COLOR B : Black G : Green P :Pink Bl : Blue Gr : Gray R : Red Br : Brown Lbl : Light blue W : White Dg : Dark green Lg : Light green Y : Yellow Dgr : Dark gray O : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/G : Black with Green tracer B/Lg : Black with Light green tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer Br/Y : Brown with Yellow tracer G/B : Green with Black tracer G/Bl : Green with Blue tracer G/R : Green with Red tracer G/W : Green with White tracer G/Y : Green with Yellow tracer Gr/B : Gray with Black tracer Gr/R : Gray with Red tracer Gr/W : Gray with White tracer Gr/Y : Gray with Yellow tracer Lg/BI : Light green with Blue tracer Lg/G : Light green with Green tracer Lg/W : Light green with White tracer O/B : Orange with Black tracer O/BI : Orange with Blue tracer O/G : Orange with Green tracer O/R : Orange with Red tracer O/W : Orange with White tracer O/Y : Orange with Yellow tracer P/B : Pink with Black tracer P/W : Pink with White tracer R/B : Red with Black tracer R/Bl : Red with Blue tracer R/Y : Red with Yellow tracer R/W : Red with White tracer W/B : White with Black tracer W/Bl : White with Blue tracer W/G : White with Green tracer W/R : White with Red tracer W/Y : White with Yellow tracer Y/B : Yellow with Black tracer Y/Bl : Yellow with Blue tracer Y/G : Yellow with Green tracer Y/R : Yellow with Red tracer Y/W : Yellow with White tracer SAMPLE

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ......................................................................... 1- 2 GENERAL PRECAUTIONS .......................................................................... 1- 2 SUZUKI GSX-R1000K5 (’05-MODEL) .......................................................... 1- 4 SERIAL NUMBER LOCATION ..................................................................... 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ....................... 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 The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-02 E-03 E-19 (GSX-R1000) E-19 (GSX-R1000UF) E-24 E-28 E-33 U.K. U.S.A. (Except for California) E.U. E.U. Australia Canada California (U.S.A.) JS1B6111200100001 – JS1GT76A 52100001 – JS1B6111100100001 – JS1B6211100100001 – JS1B6121300100001 – JS1GT76A 52100001 – JS1GT76A 52100001 – SAMPLE

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.  Indicates a potential hazard that could result in death or injury.  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 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  * 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 is 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. SAMPLE

2005-2006 GSXR 1000 Service & Repair Manual

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