Suzuki GSX-R 1000 Service Manual: 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:
- remove the side cowlings. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Disconnect the battery (–) lead wire (1).

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

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

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

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

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

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

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

- Disconnect the pair solenoid valve coupler (16).

- Disconnect the cmp sensor lead wire coupler (17)
and ignition coil couplers (18).
- 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.
|

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

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

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

- Support the engine using an engine jack.

- Loosen the engine mounting pinch bolts (22) (rh).
- Remove the engine mounting bolts (23) (rh).
- Remove the engine mounting bolts (24) (lh).

- Remove the engine mounting nut (25).
- Remove the engine mounting thrust adjuster locknut
(26) with the special tool.
- 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. |



- Remove the engine mounting nut (28).
- Loosen the engine mounting thrust adjuster lock-nut
(29) with the special tool.
- 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. |



- Remove the engine mounting bolts and gradually
lower the front side of the engine. Then, take off the
drive chain from the driveshaft.
- Remove the engine assembly.
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 ...
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:
Rear lighting system construction
License plate light assembly
Reflex reflector (e-03, 28, 33 only)
Clamp
: clamp the license plate light lead wire
so as not to be slack.
Rear combination light
Rear turn signal light assembly (lh/rh)
5
N·m (0.5 Kgf-m, 3.5 Lbf-ft)
1.8 N·m
...
Rear wheel dust seal / bearing removal and installation
Removal
Remove the rear wheel assembly. Refer to “rear wheel assembly removal
and installation” .
Remove the rear sprocket mounting drum assembly
(1) from the rear wheel.
Remove the wheel dampers (2).
Remove the dust seal.
Special tool
(a): 09913–50121 (oil s ...
Rear suspension components
Rear shock absorber
Rear shock absorber mounting nut
Cushion rod
Cushion rod mounting nut
Cushion lever
Cushion lever mounting nut
Swingarm pivot lock-nut
Swingarm pivot shaft
Swingarm pivot nut
Swingarm
Chain case
Plate
Chain adjus ...