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Suzuki GSX-R 1000 Service Manual: Fuel pump disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Engine / Fuel system / Repair instructions / Fuel pump disassembly and assembly

Disassembly

  1. Remove the fuel tank. Refer to “fuel tank removal and installation” .
  2.  Remove the fuel pump assembly (1) by removing its mounting bolts diagonally.


  • Spilled gasoline should be wipe off immediately.
  • Keep away from fire or spark.
  • Work in a well-ventilated area.

Suzuki GSX-R. Disassembly


  1. Disconnect the lead wires (2).

Suzuki GSX-R. Disassembly


  1. Remove the fuel level gauge (3).

Suzuki GSX-R. Disassembly


  1. Remove the fuel pressure regulator assembly (4).
Caution

never remove the fuel pressure regulator (5) from the holder.

Suzuki GSX-R. Disassembly


Suzuki GSX-R. Disassembly


  1. Remove the o-ring (6) and fuel pump case (7).

Suzuki GSX-R. Disassembly


  1. Remove the o-ring (8) and joint (9).
  2. Remove the o-ring (10) and lead wires (11).

Suzuki GSX-R. Disassembly


  1. Remove the fuel mesh filter (12).
  2.  Remove the fuel pump (13).

Suzuki GSX-R. Disassembly


Assembly

Refer to “fuel mesh filter inspection and cleaning” .

Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points:

Caution

  •  to prevent fuel leakage, the bushing and o-ring must be replaced with new ones.
  •  Apply engine oil lightly to the o-rings.

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


Caution

connect all lead wires securely so as not to cause contact failure.

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


  1. Fuel pump (+) lead wire (y/r)
  2. Fuel level gauge (+) lead wire (r/b)
  3. Fuel pump (–) lead wire (b/w)
  4. Fuel level gauge (–) lead wire (b/w)

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

The o-ring
must be replaced with a new one to prevent fuel leakage.

Suzuki GSX-R. Assembly


Tightening torque fuel pump mounting bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Assembly


Fuel pump components
Fuel level gauge Fuel pressure regulator assembly O-ring Joint Fuel pump Fuel pump case Fuel mesh filter 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) Appl ...

Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:  remove the fuel mesh filter. Refer to “fuel pump disassembly and assembly” .  If the fuel mesh filter is clogged with fore ...

Other materials:

Transmission removal
Remove the engine assembly from the frame. Refer to “engine assembly removal” in section 1d .  Remove the engine top side. Refer to “engine top side disassembly” in section 1d .  Separate the upper and lower crankcases. Refer to “engine bottom side disassembly” in section 1 ...

Headlight bulb and position light bulb replacement
Caution when you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. Low beam bulb Remove the combination meter. Refer to “combination meter removal and installation” in section 9c . ...

Throttle body components
Fuel delivery pipe Fuel delivery pipe t-joint O-ring Tp sensor Stp sensor Secondary fuel injector Primary fuel injector Cushion seal Isc valve Air screw Vacuum hose Evap system purge control solenoid valve For e-33 only 3.5 ...

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