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Suzuki GSX-R 1000 Service Manual: Engine assembly removal

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Engine assembly removal

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps:

  1.  remove the side cowlings. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
  2.  Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
  3.  Disconnect the battery (–) lead wire (1).

Suzuki GSX-R. Engine assembly removal


  1. Jack up the motorcycle and fix it for safety.
  2.  Drain engine oil. Refer to “engine oil and filter replacement” in section 0b .
  3.  Drain engine coolant. Refer to “engine oil and filter replacement” in section 0b .
  4.  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
  5.  Remove the air cleaner box. Refer to “air cleaner box removal and installation” .
  6.  Remove the throttle body assembly. Refer to “throttle body removal and installation” (page 1d- 10).
  7.  Remove the oil cooler and hoses. Refer to “oil cooler / oil cooler hose removal and installation” in section 1e .
  8. Remove the radiator assembly. Refer to “radiator / cooling fan motor removal and installation” in section 1f .
  9.  Disconnect the water/air bleed hose (2) and radiator inlet hose (3).

Suzuki GSX-R. Engine assembly removal


  1. Remove the horn (4) and radiator heat guard (5).

Suzuki GSX-R. Engine assembly removal


  1. Remove the radiator/oil cooler mounting bracket (6).

Suzuki GSX-R. Engine assembly removal


  1. Remove the exhaust system components. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .
  2.  Remove the clamp (7).
  3.  Disconnect the oil pressure switch lead wire coupler (8), generator lead wire coupler (9) and ect sensor coupler (10).

Suzuki GSX-R. Engine assembly removal


  1. Disconnect the gp switch lead wire coupler (11).

Suzuki GSX-R. Engine assembly removal


  1. Disconnect the starter motor lead wire (12) and engine ground lead wire (13).

Suzuki GSX-R. Engine assembly removal


  1. Disconnect the ckp sensor lead wire coupler (14).
  2. Remove the crankcase breather (pcv) hose (15).

Suzuki GSX-R. Engine assembly removal


  1. Disconnect the pair solenoid valve coupler (16).

Suzuki GSX-R. Engine assembly removal


  1. Disconnect the cmp sensor lead wire coupler (17) and ignition coil couplers (18).
  2.  Remove the ignition coils.
Caution

  •  do not remove the ignition coil before disconnecting its coupler.
  •  Do not pry up the ignition coil/plug cap with a screwdriver or a bar to avoid its damage.
  •  Be careful not to drop the ignition coil/plug cap to prevent its short or open circuit.

Suzuki GSX-R. Engine assembly removal


  1. Remove the engine sprocket cover (19). Refer to “engine sprocket removal and installation” in section 3a .

Suzuki GSX-R. Engine assembly removal


  1. Remove the dowel pins and clutch push rod (20).

Suzuki GSX-R. Engine assembly removal


  1. Remove the engine sprocket (21). Refer to “engine sprocket removal and installation” in section 3a .

Suzuki GSX-R. Engine assembly removal


  1. Support the engine using an engine jack.

Suzuki GSX-R. Engine assembly removal


  1. Loosen the engine mounting pinch bolts (22) (rh).
  2.  Remove the engine mounting bolts (23) (rh).
  3.  Remove the engine mounting bolts (24) (lh).

Suzuki GSX-R. Engine assembly removal


  1. Remove the engine mounting nut (25).
  2.  Remove the engine mounting thrust adjuster locknut (26) with the special tool.
  3. Loosen the engine mounting thrust adjuster (27) fully.

Special tool (a): 09940–14990 (engine mounting
adjust wrench)

Note do not remove the engine mounting bolt at this stage.

Suzuki GSX-R. Engine assembly removal


Suzuki GSX-R. Engine assembly removal


Suzuki GSX-R. Engine assembly removal


  1. Remove the engine mounting nut (28).
  2.  Loosen the engine mounting thrust adjuster lock-nut (29) with the special tool.
  3. Loosen the engine mounting thrust adjuster (30) fully.

Special tool (a): 09940–14990 (engine mounting
adjust wrench)

Note

do not remove the engine mounting bolt at this stage.

Suzuki GSX-R. Engine assembly removal


Suzuki GSX-R. Engine assembly removal


Suzuki GSX-R. Engine assembly removal


  1. Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft.
  2.  Remove the engine assembly.
Tp reset
When replacing the throttle body assembly or tp sensor with a new one or reinstalling the tp sensor, reset the tp learned value in the following procedures: Note keep the throttle valves ...

Engine assembly installation
Install the engine in the reverse order of engine removal. Pay attention to the following points:  before installing the engine, install the collars (1). Before installing the en ...

Other materials:

Gearshift shaft / gearshift cam plate components
Gearshift shaft Gearshift cam drive plate Gearshift cam plate Gearshift cam stopper 19 N·m (1.9 Kgf-m, 13.5 Lbf-ft) 13 N·m (1.3 Kgf-m, 9.5 Lbf-ft) 8.5 N·m (0.85 Kgf-m, 6.0 Lbf-ft) Apply grease to oil seal lip. Apply thread l ...

DTC “c41” (p0230-h/l): fp relay circuit malfunction
Detected condition and possible cause Detected condition Possible cause C41 No voltage is applied to fuel pump. Fuel pump relay circuit open or short. Fuel pump relay malfunction. Fuel pump relay switch circuit is shorted to power source. ...

Voltage check
If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.  With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.  If measurements were taken as shown ...

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