Suzuki GSX-R 1000 Service Manual: Fuel tank removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Fuel system / Repair instructions / Fuel tank removal and installation

Removal

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

Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).
Take out the fuel tank prop stay (1).

Suzuki GSX-R. Removal

Remove the bolts.

Suzuki GSX-R. Removal

Lift and support the fuel tank with the prop stay.

Suzuki GSX-R. Removal

Disconnect the fuel pump lead wire coupler (2).
Place a rag under the fuel feed hose (3) and disconnect the fuel feed hose from the fuel tank.

Caution

when removing the fuel tank, do not leave the fuel feed hose on the fuel pump side.

Disconnect the fuel tank drain hose (4).
Disconnect the surge hose (5). (For e-33)
disconnect the fuel tank breather hose. (Except for e-33)

Suzuki GSX-R. Removal

Remove the fuel tank by removing its bracket bolt (6).

Suzuki GSX-R. Removal

Installation

Install the fuel tank in the reverse order of removal.

Pay attention to the following point:

Note

connect the fuel feed hose to the fuel pump until it locks securely (a click is heard).

Fuel tank construction

Fuel tank heat shield : aluminum film side should face the engine side. Fuel tank front cover Fuel tank front bracket Velcro fastenings : clean the adhesiv ...

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 ...

Other materials:

Cylinder head disassembly and assembly
Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Intake, exhaust, no. 1 Or no. 2) So that they can be installed in their original locations ...

Turn signal / side-stand relay removal and installation
Removal Remove the frame cover. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Remove the turn signal/side-stand relay (1). Installation Install the turn signal/side-stand relay in the reverse order of removal. ...

Balancer shaft journal bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. Selection Place the plastigauge axial ...