Suzuki GSXR1000 Repair Manual 2001-2004

The 2001-2004 Suzuki GSX-R1000 sportbike repair manual by Clymer, covers models indicated.
Book Excerpt: 2001-2004 Suzuki GSXR1000 Repair Manual AIR, FUEL INJECTION, EMISSIONS AND EXHAUST SYSTEMS

FUEL PUMP The fuel pump is located inside the fuel tank and operates whenever the ignition switch is on. The pressure regulator, which is an integral part of the fuel pump, maintains fuel line pressure at 300 kPa (43 psi). If fuel pressure becomes excessive, a check valve in the regulator opens so fuel flows back into the fuel tank. This eliminates the need for a fuel return line. REMOVAL/INSTALLATION

1. Remove the fuel tank as described in this chapter. Drain the fuel into a suitable container.
2. Set the fuel tank on towels or a blanket on the workbench.
3. Evenly loosen the fuel pump bolts (Figure 9) in a crisscross pattern and remove the bolts.
4. Pull the fuel pump (A, Figure 10) from the tank. Remove and discard the fuel pump O-ring (B, Figure 10).
5. Installation is the reverse of removal.
1. Apply Suzuki Super Grease A to a new O-ring, and fit the O-ring into the channel in the tank (B, Figure 10).
2. Apply Suzuki Thread Lock 1342, or its equivalent, to the threads of the fuel pump bolts and install the bolts (Figure 9).
3. Evenly tighten the bolts in a crisscross pattern to 10 N.m (89 in.-lb.).


6. Install the fuel tank.

WHEELS, TIRES AND DRIVE CHAIN

TIRES: SAFETY Break in new tires correctly. A new tire has relatively poor adhesion to the road surface until it is broken in properly. Do not subject a new tire to hard cornering, hard acceleration or hard braking for the first 100 miles (160 km). If you purchased a tire other those originally installed, maintain the correct tire inflation pressure recommended by the manufacturer. The recommended inflation pressure listed in Table 1 applies to Suzuki original equipment tires only.

Subject: 2001, 2002, 2003, 2004 Suzuki GSX-R1000 service, maintenance, repair. ISBN-10: 0892879270 | ISBN-13: 9780892879274 | Clymer M377