Suzuki GSX-R 1000 Service Manual: Muffler / muffler chamber / exhaust pipe
removal and installation
Removal
- Loosen the muffler connecting bolts (1).
- Remove the mufflers (2) by removing the mounting
bolt and nut (3).
Note
support the muffler to prevent it from falling. |


- Remove the side cowlings. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
- Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
- Disconnect the ho2 sensor coupler (4).

- Remove the muffler chamber heat guard no. 2 (5).
(Rh only)

- Loosen the muffler chamber connecting bolt (6).
- Remove the muffler chamber (7).


- Remove the muffler chamber heat guard no. 1 (8)
And ho2 sensor (9) from the muffler chamber.
Caution
- be careful not to expose the ho2 sensor to
an excessive shock.
- Be careful not to twist or damage the ho2
sensor lead wires.
|

- Remove the excv cables (10). Refer to “excv cable removal and
installation” .

- Move the radiator and oil cooler forward. Refer to “radiator inspection
and cleaning” in section 1f .
- Remove the exhaust pipe assembly by removing the
exhaust pipe bolts.
Caution
take care not to bend the radiator/oil cooler
fins. |
Note
support the exhaust pipe assembly to
prevent it from falling. |

- Remove the exhaust pipe gaskets (11).

Installation
Installation is in the reverse order of removal. Pay
attention to the following points:
- tighten the ho2 sensor to the specified torque.
Tightening torque
ho2 sensor (a): 25 n·m (2.5 Kgf-m, 18.0 Lbf-ft)
Caution
- be careful not to expose the ho2 sensor to
an excessive shock.
- Do not use an impact wrench when
installing the ho2 sensor.
- Be careful not to twist or damage the ho2
sensor lead wires.
- Do not apply oil or other materials to the
sensor air holes.
|

- Install new gaskets and connectors and tighten each bolt to the
specified torque. Refer to “exhaust system components” .
Caution
replace the gaskets and connectors with
new ones. |
Note
when installing a new connector, remove all
of the old sealer. Apply the exhaust gas
sealer to both the inside and outside of the
new connector. |
: Muffler seal (muffler
seal loctite
5920 (commercially available) or equivalent)
- Install the excva cables. Refer to “excv cable removal and installation”
.
Inspect the excva operation and adjust it if necessary
in the following steps:
Step 1
Set the excva to the adjustment position. Refer to
“excv cable removal and installation” (page 1k-
6).
...
Inspect the exhaust pipe, muffler chamber and muffler
connection for exhaust gas leakage and mounting
condition. If any defect is found, replace the exhaust
pipe, muffler chamber or muffler with a ...
Other materials:
Conclusion
Traffic, road and weather conditions
vary. Other motorists'
actions are unpredictable. Your
motorcycle's condition can
change. These factors can best
be dealt with by giving every ride
your full attention.
Circumstances beyond your control
could lead to an accident. You
need to prepare fo ...
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Exhaust system components”
Special tool
...
Exhaust control system construction
Excv cable no. 1 (Cl)
Excv cable no. 2 (Op)
When
loosening or tightening the pulley bolt, be sure to fix the
pulley with an adjustable wrench, or excva may get damaged.
5 N·m (0.5 Kgf-m, 3.5 Lbf-ft)
42 – 43 Mm (1.65 – 1.69 In)
60 – 61 Mm (2.36 – ...