Description
This Clymer Suzuki GSX-R1000 2001 2002 2003 2004 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2001-2004 Suzuki GSX-R1000 motorcycles.
The purpose of this manual is to help you get the best value from your motorcycle. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. This book should allow you to tackle any job yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.
This book covers maintenance, and will provide you with everything you need to service and repair your engine, clutch and transmission, fuel system, lubrication system, ignition system, frame, forks, wheels, brakes, tires and electrical system. This book includes complete wiring diagrams.
Table of Contents
QUICK REFERENCE DATA
CHAPTER ONE/GENERAL INFORMATION
Manual organization/Warnings, cautions and notes/Safety/Serial numbers/Fasteners/Shop supplies/Basic tools/Precision measuring tools/Electrical system fundamentals/Basic service methods/Storage/Specifications
CHAPTER TWO/TROUBLESHOOTING
Engine principles/Starting the engine/Engine will not start/Engine performance/Engine noises/Engine lubrication/Cylinder leakdown test/Clutch/Gearshift linkage/Transmission/Fuel system/Fuel pump troubleshooting/Electrical testing/Electrical troubleshooting/Steering and suspension/Brake system
CHAPTER THREE/LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel/Cylinder numbering and firing order/Engine rotation/Maintenance intervals/Tune-up/Ignition timing/Valve clearance/Spark plugs/Engine oil and filter/Engine oil pressure test/Throttle cable free play/Idle speed adjustment/Fast idle speed/Throttle valve/Synchronization/Fuel line inspection/Emission control systems/Exhaust control valve/Clutch adjustment/Shift pedal height/Cooling system/Tires and wheels/Front suspension/Steering check/Rear suspension/Drive chain/Brake system/General lubrication/Fastener inspection/Specifications
CHAPTER FOUR/ENGINE TOP END
Cylinder head cover/Camshaft/Cam chain tensioner/Cam chain, chain guides and timing rotor/Cylinder head/Valve lifter and shim/Valves and valve components/Pistons and cylinder block/Specifications
CHAPTER FIVE/ENGINE LOWER END
Servicing engine in frame/Engine service notes/Engine/Starter idler cover/Starter clutch and gears/Alternator cover/Flywheel/Oil pump/Oil cooler/Oil pan and strainer/Crankcase/Crankshaft/Balancer shaft/Connecting rod/Piston and piston rings/Engine break-in/Specifications
CHAPTER SIX/CLUTCH
Clutch cover/Clutch release mechanism/Clutch cable replacement/Clutch lever assembly/Specifications
CHAPTER SEVEN/TRANSMISSION, SHIFT MECHANISM AND ENGINE SPROCKET
Engine sprocket cover/Engine sprocket/Shift pedal/footrest/External shift mechanism/Internal shift mechanism/Transmission/ Specifications
CHAPTER EIGHT/AIR, FUEL INJECTION, EMISSIONS AND EXHAUST SYSTEMS
Fuel tank/Fuel pump/Fuel pump relay/Pressure regulator/Air filter housing/Throttle bodies/Fuel injectors/Throttle position (TP) sensor/Secondary throttle position (STP) sensor/Secondary throttle valve actuator (STVA)/Throttle cable /Fast idle (choke)/Atmospheric pressure (AP) sensor/Camshaft position (CMP) sensor/Engine coolant temperature (ECT) sensor/Intake air pressure (IAP) sensor/Intake air temperature (IAT) sensor/Tip over (TO) sensor/Exhaust system/Exhaust control valve/Exhaust control valve actuator (EXCVA)/Evaporative emissions control system /Pair system/Self-diagnosis fuel injection troubleshooting/Specifications
CHAPTER NINE/ELECTRICAL SYSTEM
Electrical basics/Electrical connectors/Battery/Charging system/Voltage regulator/rectifier/Stator coil/Ignition system/Crankshaft position (CKP) sensor/Ignition coil/plug cap/Starting system/Starter motor/Starter relay/Sidestand switch/Gear position (GP) sensor/Turn signal/sidestand relay/Lighting system/Horn/Meter assembly/Speed sensor/Oil pressure switch/Switches/Fuses/Wiring and connectors/Wiring diagrams/Specifications
CHAPTER TEN/COOLING SYSTEM
Hoses and hose clamps/Cooling system inspection/Coolant reservoir/Radiator/Thermo switch/Radiator fan/Radiator fan relay/Engine coolant temperature sensor/Thermostat/Water pump/Specifications
CHAPTER ELEVEN/WHEELS, TIRES AND DRIVE CHAIN
Motorcycle stand/Brake rotor protection/Front wheel/Wheel inspection/Rear wheel/Rear coupling and rear sprocket/Bearing inspection/Front hub/Rear hub/Wheel balance/Tires/Tubeless tire changing/Tire repairs/Drive chain/Specifications
CHAPTER TWELVE/FRONT SUSPENSION AND STEERING
Handlebar/Handlebar left grip/Steering head and stem/Steering head bearing race/Steering stem race/Steering damper/Front fork/Specifications
CHAPTER THIRTEEN/REAR SUSPENSION
Shock absorber/Suspension linkage/Swing arm/Bearing replacement/Swing arm pivot boss/Specifications
CHAPTER FOURTEEN/BRAKES
Brake service/Brake bleeding tips/Bleeding the brakes/Brake fluid draining/Brake pad inspection/Front brake caliper /Front brake master cylinder/Rear brake caliper/Rear brake master cylinder/Brake pedal/footpeg assembly/Brake disc/Brake hose replacement/Specifications
CHAPTER FIFTEEN/BODY AND FRAME
Body panel fasteners/Rider seat/Passenger seat/tail cover/Front engine cover/Center cover/Bracket cover/Mirror/Windshield/Front fairing/Fairing bracket/Intake duct/Side fairing/Tail piece/Front fender/Sidestand/Specifications
INDEX
WIRING DIAGRAMS
