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Printed in USA
K5 K6
543
1.0625
GSX-R1000
Service
Manual
*99500-39271-03E*
* 9 9 5 0 0 - 3 9 2 7 1 - 0 3 E *
IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to
Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service this street-legal motorcycle in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and FI
System and Fuel System be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL
PROGRAM MANUAL/SERVICE BULLETIN.
Prepared by
2005
Part No. 99500-39271-03E
Printed in U.S.A.
543
SUPPLEMENTS
GSX-R1000K6
WIRING DIAGRAM
12
13
2-30 PERIODIC MAINTENANCE
CHASSIS BOLTS AND NUTS
Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the locations of the following nuts and bolts on the motorcycle.)
Item
1 Steering stem head nut
2 Steering stem lock-nut
3 Front fork upper clamp bolt
4 Front fork lower clamp bolt
5 Front fork cap bolt
6
Front axle bolt
7 Front axle pinch bolt
N•m
90
90
23
23
23
100
23 kgf-m
9.0
9.0
2.3
2.3
2.3
10.0
2.3
Ib-ft
6.5
65.0
16.5
16.5
16.5
72.5
16.5
8 Handlebar clamp bolt
9 Front brake master cylinder mounting bolt
0 Front brake caliper mounting bolt
A Front brake caliper housing bolt
B Brake hose union bolt (Front & Rear)
C Air bleeder valve (Front brake caliper)
D Air bleeder valve (Master cylinder & Rear brake caliper)
E Brake disc bolt (Front)
F
Brake disc bolt (Rear)
G Rear brake caliper mounting bolt
23
10
39
22
23
7.5
6.0
23
35
2.3
1.0
3.9
2.2
2.3
0.75
0.6
2.3
3.5
16.5
7.0
28.0
16.0
16.5
5.5
4.5
16.5
25.5
25 2.5
18.1
H Rear brake caliper housing bolt
I Rear brake master cylinder mounting bolt
J Rear brake master cylinder rod lock-nut
K Front footrest bracket mounting bolt
L Swingarm pivot nut
M Swingarm pivot lock-nut
37
10
18
23
100
3.7
1.0
1.8
2.3
10.0
27.0
7.0
13.0
16.5
72.5
90 9.0
65.0
N Rear suspension bracket nut
O Rear shock absorber mounting bolt/nut (Upper & Lower)
P
Cushion rod nut
Q Cushion lever mounting nut
115
50
78
11.5
5.0
7.8
83.0
36.0
56.5
T Steering damper bolt/nut
78
R Rear axle nut 100 10.0
72.5
S Rear sprocket nut 60 6 .
0 43 .5
23
7.8
2.3
56.5
16.5
8-44 CHASSIS
REASSEMBLY AND INSTALLATION
Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points:
Left
100 N·m
(10.0 kgf-m, 72.5 lb-ft)
60 N·m
( 6 .
0 kgf-m, 43 .5 lb-ft)
Right
35 N·m
(3.5 kgf-m, 25.5 lb-ft)
E-02, 19, 24
E-03, 28, 33
100 N·m
(10.0 kgf-m, 72.5 lb-ft)
25 N·m
(2.5 kgf-m, 18.0 lb-ft)
• Tighten the sprocket mounting nuts to the specified torque.
Rear sprocket nut: 60 N·m ( 6 .
0 kgf-m, 43 .5 lb-ft)
NOTE:
Stamped mark A on the sprocket should face outside.
• Install the collar 2 .
BRAKE DISC
• Apply THREAD LOCK to the disc bolts and tighten them to the specified torque.
NOTE:
Make sure that the brake disc is clean and free of any greasy matter.
99000-32130: THREAD LOCK SUPER “1360”
Brake disc bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft)
• Install the collar 1 .
REAR AXLE
• Remount the rear wheel and rear axle shaft, and install the washer 1 (Except for E-03, 28, 33) and rear axle nut 2 .
• Adjust the chain slack after rear wheel installation. (
2-21)
CHASSIS 8-47
9-36 ELECTRICAL SYSTEM
HEADLIGHT BEAM ADJUSTMENT
• Adjust the headlight beam.
NOTE:
* Use a screw driver + for adjuster A , B and C .
* To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically.
A : Horizontal adjuster (Low beam)
B : Vertical adjuster (Low beam)
C : Horizontal adjuster (Hi gh beam)
D
: Vertical adjuster (
High
beam)
SERVICING INFORMATION 10-47
CHASSIS
Steering stem head nut
Steering stem lock-nut
Steering damper bolt and nut
Front fork upper clamp bolt
Front fork lower clamp bolt
Front fork cap bolt
Front fork inner rod lock-nut
Front fork damper rod bolt
Front axle bolt
Front axle pinch bolt
Handlebar clamp bolt
ITEM
Front brake master cylinder mounting bolt
N·m
39
22
15
23
100
23
23
10
23
23
29
23
90
90
23
23 kgf-m
10.0
2.3
2.3
1.0
3.9
2.2
1.5
2.3
2.3
2.3
2.9
2.3
9.0
9.0
2.3
2.3
lb-ft
Front brake caliper mounting bolt
Front brake caliper housing bolt
Front brake pad mounting pin
Brake hose union bolt
Clutch lever holder mounting bolt
Air bleeder valve (Front brake caliper)
Air breeder valve (Master cylinder and Rear brake caliper)
Brake disc bolt (Front)
Brake disc bolt (Rear)
Rear brake caliper mounting bolt
Rear brake caliper housing bolt
Rear brake pad mounting pin
Rear brake master cylinder mounting bolt
Rear brake master cylinder rod lock-nut
Front footrest bracket mounting bolt
Swingarm pivot shaft
Swingarm pivot nut
Swingarm pivot lock-nut
Swingarm pivot boss nut
Cushion lever mounting nut
Cushion rod mounting nut
10
7.5
6.0
23
35
25
37
17
10
18
23
15
100
90
65
78
78
1.0
0.75
0.6
2.3
3.5
2.5
3.7
1.7
1.0
1.8
2.3
1.5
10.0
9.0
6.5
7.8
7.8
Rear shock absorber mounting bolt and nut
(Upper and Lower)
50 5.0
36.0
Rear axle nut 100 10.0
72.5
Rear sprocket nut
60 6
.
0 43
.5
Side-stand mounting bracket bolt 50 5.0 36.0
Cowling brace bolt and nut
Rear shock absorber bracket nut
Seat rail bolt
Rear view mirror nut
23
115
50
10
2.3
11.5
5.0
1.0
16.5
83.0
36.0
7.0
7.0
5.5
4.3
16.5
25.5
18.0
27.0
12.5
7.0
13.0
16.5
11.0
72.5
65.0
47.0
56.5
56.5
72.5
16.5
16.5
7.0
28.0
16.0
11.0
16.5
65.0
65.0
16.5
16.5
16.5
16.5
21.0
16.5
GSX-R1000K6
12
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
2 030 mm (79.9 in)
Overall width........................................................................................
710 mm (28.0 in)
Overall height ......................................................................................
1 130 mm (44.5 in)
Wheelbase ..........................................................................................
1 405 mm (55.3 in)
Ground clearance................................................................................
130 mm (5.1 in)
Seat height ..........................................................................................
810 mm (31.9 in)
Dry mass .............................................................................................
167 kg (368 lbs) ....... E-33
166 kg (365 lbs) ....... Others
ENGINE
Type.....................................................................................................
Four stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................
4
Bore.....................................................................................................
73.4 mm (2.900 in)
Stroke ..................................................................................................
59.0 mm (2.323 in)
Displacement ......................................................................................
999 cm 3 (61.0 cu. in)
Compression ratio ...............................................................................
12.5 : 1
Fuel system .........................................................................................
Fuel injection
Air cleaner ...........................................................................................
Paper element
Starter system .....................................................................................
Electric
Lubrication system ..............................................................................
Wet sump
Idle speed............................................................................................
1 150 ± 100 r/min
DRIVE TRAIN
Clutch ..................................................................................................
Wet multi-plate type
Transmission .......................................................................................
6-speed constant mesh
Gearshift pattern ................................................................................
1-down, 5-up
Primary reduction ratio ........................................................................
1.553 (73/47)
Gear ratios, Low ................................................................................
2.562 (41/16)
2nd ................................................................................
2.052 (39/19)
3rd .................................................................................
1.714 (36/21)
4th .................................................................................
1.500 (36/24)
5th .................................................................................
1.360 (34/25)
Top.................................................................................
1.269 (33/26)
Final reduction ratio.............................................................................
2.470 (42/17)
Drive chain ..........................................................................................
DID530, 110 links
CHASSIS
Front suspension.................................................................................
Inverted telescopic, coil spring, oil damped
Rear suspension .................................................................................
Link type, coil spring, oil damped
Front fork stroke ..................................................................................
120 mm (4.7 in)
Rear wheel travel ................................................................................
130 mm (5.1 in)
Steering angle .....................................................................................
27°
Caster..................................................................................................
23° 45’
Trail......................................................................................................
96 mm (3.78 in)
Turning radius......................................................................................
3.4 m (11.2 ft)
Front brake ..........................................................................................
Disc brake, twin
Rear brake...........................................................................................
Disc brake
Front tire size.......................................................................................
120/70ZR17M/C (58 W), tubeless
Rear tire size .......................................................................................
190/50ZR17M/C (73 W), tubeless
ELECTRICAL
Ignition type.........................................................................................
Electronic ignition (Transistorized)
Ignition timing ......................................................................................
10° B.T.D.C. at 1 150 r/min
Spark plug ...........................................................................................
NGK CR9E or DENSO U27ESR-N
Battery.................................................................................................
12 V 36.0 kC (10 Ah)/10 HR
Generator ............................................................................................
Three phase A.C. generator
Main fuse.............................................................................................
30 A
Fuse ....................................................................................................
15/10/10/10/10/10 A
Headlight .............................................................................................
12 V 55 W (H7) + 12 V 60 W (HB3)
Turn signal light ...................................................................................
12 V 21 W
License plate light ...............................................................................
12 V 5 W
Brake light/Taillight ..............................................................................
LED
Speedometer light ...............................................................................
LED
Tachometer light ..................................................................................
LED
Neutral indicator light...........................................................................
LED
High beam indicator light.....................................................................
LED
Turn signal indicator light.....................................................................
LED
Position/Parking light ...........................................................................
12 V 5 W × 2
Oil pressure/Coolant temperature/Fuel injection warning light............
LED
Fuel level indicator light.......................................................................
LED
Engine RPM indicator light ..................................................................
LED
Imobirizer indicator light ......................................................................
LED ................ E-02,19, 24
CAPACITIES
Fuel tank, including reserve ...............................................................
17.5 L (4.6/3.8 US/Imp gal)....... E-33
18.0 L (4.8/4.0 US/Imp gal)....... Others
Engine oil, oil change.........................................................................
3 000 ml (3.2/2.6 US/Imp qt) with filter change ..............................................................
3 300 ml (3.5/2.9 US/Imp qt) overhaul............................................................................
3 600 ml (3.8/3.2 US/Imp qt)
Coolant................................................................................................
2.4 L (2.5/2.1 US/Imp qt)
– 2 –
SERVICE DATA
VALVE + VALVE GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve seat width
Valve head radial runout
Valve spring free length
Valve spring tension
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
30
(1.18)
24
(0.94)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1772 – 0.1776)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
—
—
0.9 – 1.1
(0.035 – 0.043)
—
—
Approx. 147 N (15.0 kgf, 33.1 lbs) at length 33.55 mm (1.32 in)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
37.58 – 37.63
(1.480 – 1.481)
36.28 – 36.33
(1.428 – 1.430)
0.032 – 0.066
(0.0013 – 0.0026)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
—
—
—
—
—
0.25
(0.010)
0.05
(0.002)
—
0.03
(0.001)
37.5
(1.48)
—
Unit: mm (in)
LIMIT
—
—
—
—
Unit: mm (in)
LIMIT
37.28
(1.468)
35.98
(1.417)
0.150
(0.0059)
—
—
– 3 –
ITEM
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
STANDARD
—
14th pin
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
Compression pressure difference
—
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.035 – 0.045
(0.0014 – 0.0018)
73.400 – 73.415
(2.8900 – 2.8903)
73.360 – 73.375
(2.8882 – 2.8888)
Measure at 15 mm (0.6 in) from the skirt end.
—
Piston ring free end gap
1st Approx. 6.5 (0.26)
Piston ring end gap
Piston ring to groove clearance
2nd T
1st
2nd T
1st
Approx. 8.0 (0.31)
0.06 – 0.18
(0.002 – 0.007)
0.06 – 0.18
(0.002 – 0.007)
—
Piston ring groove width
Piston ring thickness
Piston pin bore I.D.
Piston pin O.D.
2nd
1st
2nd
Oil
1st
2nd
—
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
1.51 – 1.53
(0.0594 – 0.0602)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
15.002 – 15.008
(0.5906 – 0.5909)
14.995 – 15.000
(0.5903 – 0.5906)
LIMIT
0.10
(0.004)
—
0.20
(0.008)
Unit: mm (in)
LIMIT
1 000 kPa
(10 kgf/cm 2 , 142 psi)
200 kPa
(2 kgf/cm 2 , 28 psi)
0.120
(0.0047)
Nicks or
Scratches
73.280
(2.8850)
0.02
(0.008)
5.2
(0.20)
6.4
(0.25)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
—
—
15.030
(0.5917)
14.980
(0.5898)
– 4 –
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Right side
Left side
Crankshaft thrust clearance
Crankshaft runout
BALANCER
ITEM
Balancer shaft journal oil clearance
Balancer shaft journal O.D.
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
15.010 – 15.018
(0.5909 – 0.5913)
0.10 – 0.20
(0.004 – 0.008)
19.95 – 20.00
(0.7854 – 0.7874)
20.10 – 20.15
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
34.976 – 35.000
(1.3770 – 1.3780)
0.010 – 0.028
(0.0004 – 0.0011)
34.982 – 35.000
(1.3772 – 1.3780)
2.420 – 2.440
(0.0953 – 0.0961)
2.360 – 2.500
(0.0929 – 0.0984)
0.060 – 0.110
(0.0024 – 0.0043)
—
STANDARD
0.028 – 0.052
(0.0011 – 0.0020)
22.976 – 22.992
(0.9046 – 0.9052)
STANDARD
100 – 400 kPa
(1.0 – 4.0 kgf/cm², 14 – 57 psi) at 3 000 r/min
Unit: mm (in)
LIMIT
15.040
(0.5921)
0.30
(0.012)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
0.05
(0.002)
Unit: mm (in)
LIMIT
0.080
(0.0031)
—
LIMIT
—
– 5 –
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free height
Clutch lifter adjusting pin screw height
Wave spring washer height
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack (on side-stand)
Gearshift lever height
No. 1, 2 and 3
No. 1, 2 and 3
STANDARD
10 – 15
(0.4 – 0.6)
1/2 turn back
2.72 – 2.88
(0.107 – 0.113)
13.85 – 13.96
(0.5453 – 0.5496)
—
57.01
(2.244)
0.2 – 0.4
(0.008 – 0.016)
—
Type
Links
20-pitch length
STANDARD
1.553 (73/47)
2.470 (42/17)
2.562 (41/16)
2.052 (39/19)
1.714 (36/21)
1.500 (36/24)
1.360 (34/25)
1.269 (33/26)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
DID530 V9
110 links
—
20 – 30
(0.79 – 1.18)
50 – 60
(1.97 – 2.36)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.57)
—
—
Unit: mm (in)
LIMIT
—
—
2.42
(0.095)
13.05
(0.5138)
0.10
(0.004)
54.2
(2.134)
—
4.30
(0.169)
– 6 –
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
STANDARD/SPECIFICATION
Approx. 82 °C (180 °F)
8 mm (0.31 in) and over at 95 °C (203 °F)
ECT sensor resistance
50 °C
(122 °F)
80 °C
(176 °F)
Approx. 0.811 k
Approx. 0.318 k
Ω
Ω
110 °C
(230 °F)
Approx. 0.142 k Ω
Radiator cap valve opening pressure
Cooling fan operating temperature OFF → ON
ON → OFF
Engine coolant type
93 – 123 kPa
(0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)
Approx. 105 °C (221 °F)
Approx. 100 °C (212 °F)
Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
Engine coolant
20 °C
(68 °F) ratio of 50:50.
Reserve tank side
Engine side
Approx. 2.45 k
Ω
Approx. 250 ml
(0.3/0.2 US/lmp qt)
Approx. 2 150 ml
(2.3 – 1.9 US/lmp qt)
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM SPECIFICATION
Injector resistance
(primary and secondary)
Fuel pump discharge amount
Fuel pressure regulator operating set pressure
11 – 13
Ω at 20 °C (68 °F)
168 ml (5.7/5.9 US/lmp oz) and more/10 sec.
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
NOTE
NOTE
—
—
—
—
—
—
—
—
—
—
—
—
– 7 –
FI SENSORS
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor output voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor output voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
EXCVA position sensor input voltage
EXCVA position sensor resistance
EXCVA position sensor output voltage
PAIR control solenoid valve resistance
Closed
SPECIFICATION
0.9 – 1.7 k Ω
0.5 V and more
142 – 194 Ω
0.5 V and more
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Approx. 4.68 k Ω
Approx. 1.1 k Ω
Approx. 4.3 k
Ω
Approx. 1.1 V
Opened
Closed
Opened Approx. 4.3 V
4.5 – 5.5 V
0.15 – 4.85 V
Approx. 2.45 k Ω at 20 °C (68 °F)
4.5 – 5.5 V
0.15 – 4.85 V
Approx. 2.45 k Ω at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.6 V at 760 mmHg (100 kPa)
16.5 – 22.3 k Ω
Normal 0.4 – 1.4 V
Leaning 3.7 – 4.4 V
Closed
Opened
Closed
Opened
0.6 V and more
Battery voltage
80 V and more
4.5 – 5.5 V
Approx. 4.69 k Ω
Approx. 0.5 k
Ω
Approx. 3.9 k
Ω
Approx. 0.5 V
Approx. 3.9 V
Approx. 6.5 Ω
4.5 – 5.5 V
Approx. 3.1 k
Ω
Closed
Opened
0.5 – 1.3 V
3.7 – 4.5 V
18 – 22
Ω
at 20 – 30 °C (68 – 86 °F)
NOTE
When cranking
When cranking
When leaning 65°
From 1st to Top
When cranking
At adjustment position
– 8 –
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
SPECIFICATION
44 mm
41G1 (For E-33), 41G0 (For the others)
1 150 ± 100 r/min
1 400 – 2 000 r/min (When cold engine)
2.0 – 4.0 mm
(0.08 – 0.16 in)
ELECTRICAL
Firing order
Spark plug
ITEM
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Type
Gap
Primary
SPECIFICATION
1.2.4.3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
142 – 194 Ω
0.5 V and more
1.1 – 1.9
Ω
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
GP switch voltage
Battery Type designation
Capacity
Fuse size
Headlight
HI
LO
Signal
Ignition
Fuel
Fan
Main
Secondary 10.8 – 16.2 k Ω
80 V and more
0.2 – 0.9 Ω
65 V (AC) and more at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3 – 6
12 V 36 kC (10 Ah)/10 HR
10 A
10 A
10 A
10 A
10 A
15 A
30 A
Ω
0.6 V and more (From 1st to Top)
FT12A-BS
Unit: mm (in)
NOTE
When cranking
Terminal –
Terminal
Plug cap –
Terminal
When cranking
– 9 –
WATTAGE
ITEM
Headlight HI
LO
Position/Parking light
Brake light/Taillight
Turn signal light
License plate light
Combination meter light
Turn signal indicator light
High beam indicator light
Neutral indicator light
FI indicator light/Oil pressure indicator light/Engine coolant temp. indicator light
Fuel level indicator light
Engine RPM indicator light
Immobilizer indicator light
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam
Brake caliper cylinder bore
Brake caliper piston diam
Brake fluid type
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Unit: W
STANDARD/SPECIFICATION
E-03, 28, 33
60
55
5 × 2
LED
21 × 4
5
LED
LED
LED
LED
Others
←
←
←
←
←
←
←
←
←
←
LED
←
LED
LED
←
←
LED
STANDARD
55 – 65
(2.2 – 2.6)
Leading
5.3 – 5.7
(0.209 – 0.224)
4.8 – 5.2
(0.189 – 0.205)
—
19.050 – 19.093
(0.7500 – 0.7517)
14.000 – 14.043
(0.5512 – 0.5529)
19.018 – 19.034
(0.7487 – 0.7494)
13.957 – 13.984
(0.5495 – 0.5506)
30.280 – 30.356
(1.1921 – 1.1951)
Trailing
Leading
34.010 – 34.086
(1.3390 – 1.3420)
38.180 – 38.230
(1.5031 – 1.5051)
30.150 – 30.200
(1.1870 – 1.1890)
Trailing
38.080 – 38.130
(1.4992 – 1.5012)
DOT 4
33.884 – 33.934
(1.3340 – 1.3360)
—
—
—
—
—
—
—
Unit: mm (in)
LIMIT
—
5.0
(0.20)
4.5
(0.18)
0.30
(0.012)
—
—
—
—
– 10 –
ITEM
Wheel rim runout
Wheel rim size
Wheel axle runout
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Cold inflation tire pressure
(Dual riding)
Tire size
Tire type
Tire tread depth
(Recommended depth)
Axial
Radial
Front
Rear
Front
Rear
STANDARD
—
—
17 M/C × MT 3.50
17 M/C × MT 6.00
—
—
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD
250 kPa
(2.50 kgf/cm², 36 psi)
290 kPa
(2.90 kgf/cm², 42 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
290 kPa
(2.90 kgf/cm², 42 psi)
120/70 ZR17 M/C (58 W)
190/50 ZR17 M/C (73 W)
E-02, 19
Others
E-02, 19
Others
BRIDGESTONE:
BT014F SJ
BRIDGESTONE:
BT014F J
BRIDGESTONE:
BT014R J
BRIDGESTONE:
BT014R E
—
—
LIMIT
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
—
—
—
—
—
LIMIT
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
– 11 –
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring, outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Front fork damping force adjuster
(For E-02, 19)
Front fork damping force adjuster
(For E-03, 24, 28, 33)
Rear shock absorber spring pre-set length
Rear shock absorber damping force adjuster
Rear wheel travel
STANDARD
120
(4.92)
230.0
(9.06)
101
(3.98)
SUZUKI FORK OIL L01 or an equivalent fork oil
510 ml
(17.2/17.9 US/Imp oz)
4 th groove from top
Rebound 11 clicks out from stiffest position
Compression 16 clicks out from stiffest position
Rebound 9 clicks out from stiffest position
Compression 14 clicks out from stiffest position
177.6
(6.99)
Rebound 12 clicks out from stiffest position
Compression 14 clicks out from stiffest position
130
(5.1)
Swingarm pivot shaft runout
—
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended.
Including reserve
17.5 L
(4.6/3.8 US/lmp gal)
18 L
(4.8/4.0 US/lmp gal)
Fuel level indicator light lighting
Approx. 4.5 L
(1.2/1.0 US/lmp gal)
SAE 10 W-40, API SF/SG or SH/SJ with JASO MA
Change
3.0 L
(3.2/2.6 US/lmp qt)
Filter change
3.3 L
(3.5/2.9 US/lmp qt)
Overhaul
3.6 L
(3.8/3.2 US/lmp qt)
NOTE
E-03, 28, 33
Others
E-33
Others
Unit: mm (in)
LIMIT
—
225
(8.86)
—
—
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
– 12 –
BATTERY HOLDER CUSHION RUBBER INSTALLATION
Forward
– 13 –
13
IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to
Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service this street-legal motorcycle in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and FI
System and Fuel System be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL
PROGRAM MANUAL/SERVICE BULLETIN.
Prepared by
2005
Part No. 99500-39271-03E
Printed in U.S.A.
543
Printed in USA
K5 K6
543
1.0625
GSX-R1000
Service
Manual
*99500-39271-03E*
* 9 9 5 0 0 - 3 9 2 7 1 - 0 3 E *
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