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• Suzuki Gsx R1000

How to replace top cap of front fork in suzuki gsxr 1000 K7 - Answered by a verified Motorcycle Mechanic We use cookies to give you the best possible experience on our website. By continuing to use this site you consent to the use of cookies on your device as described in our cookie policy unless you have disabled them.

• 2

  Foreword
• 2

  Group Index
• 3

  How to Use This Manual
• 3

  Component Parts and Work to Be Done
• 4

  Symbol
• 5

  Abbreviations Used in This Manual
• 7

  Wire Color
• 8

  General Information
• 8

  Contents
• 9

  Warning/Caution/Note
• 11

  Suzuki GSX-R600K4 ('04-Model) View
• 11

  Serial Number Location
• 12

  Fuel, Oil and Engine Coolant Recommendation Fuel (For USA and Canada)
• 12

  Fuel (For Other Countries)
• 12

  Engine Oil (For USA)
• 12

  Engine Oil (For Other Countries)
• 13

  Engine Coolant
• 13

  Water for Mixing
• 13

  Anti-Freeze/Engine Coolant
• 13

  Liquid Amount of Water/Engine Coolant
• 14

  Break-In Procedures
• 14

  Cylinder Identification
• 15

  Information Labels
• 16

  Specifications
• 16

  Dimensions and Dry Mass
• 16

  Drive Train
• 17

  Electrical
• 17

  Capacities
• 18

  Periodic Maintenance
• 19

  Periodic Maintenance Schedule
• 19

  Periodic Maintenance Chart
• 20

  Lubrication Points
• 21

  Maintenance and Tune-up Procedures
• 21

  Air Cleaner
• 22

  Spark Plug and Ignition Coil/Plug Cap Removal
• 22

  Heat Range
• 22

  Carbon Deposits
• 23

  Spark Plug Gap
• 23

  Electrode's Condition
• 23

  Spark Plug and Ignition Coil/Plug Cap Installation
• 24

  Valve Clearance
• 26

  Valve Clearance Adjustment
• 27

  Intake Side
• 27

  Tappet Shim Selection Table
• 28

  Exhaust Side
• 29

  Engine Oil and Oil Filter
• 29

  Engine Oil Replacement
• 30

  Oil Filter Replacement
• 31

  Fuel Line
• 31

  Engine Idle Speed
• 32

  Throttle Valve Synchronization
• 32

  Evaporative Emission Control Sys­tem (E-33 Only)
• 32

  Pair (Air Supply) System
• 33

  Throttle Cable Play
• 33

  Clutch
• 34

  Cooling System
• 34

  Engine Coolant Level Check
• 34

  Engine Coolant Change
• 35

  Air Bleeding the Cooling Circuit
• 36

  Radiator Hoses
• 37

  Drive Chain
• 37

  Checking
• 38

  Adjusting
• 39

  Cleaning and Lubricating
• 40

  Brake Fluid Level Check
• 41

  Brake Pads
• 41

  Front Brake
• 41

  Rear Brake
• 41

  Brake Pedal Height
• 42

  Brake Light Switch
• 42

  Air Bleeding From Brake Fluid Circuit
• 42

  Front Brake (Caliper Side)
• 43

  Front Brake (Master Cylinder Side)
• 44

  Tire Tread Condition
• 44

  Tire Pressure
• 45

  Steering
• 45

  Front Fork
• 45

  Rear Suspension
• 46

  Exhaust Pipe Bolt and Muffler Bolt and Nut
• 47

  Chassis Bolts and Nuts
• 49

  Compression Pressure Check
• 49

  Compression Pressure Specification
• 49

  Compression Test Procedure
• 50

  Oil Pressure Check
• 50

  Oil Pressure Specification
• 50

  Oil Pressure Test Procedure
• 52

  Engine
• 53

  Engine Components Removable With Engine in Place
• 53

  Engine Center
• 53

  Engine Right Side
• 53

  Engine Left Side
• 54

  Engine Removal
• 55

  Radiator
• 56

  Exhaust Pipe and Muffler
• 57

  Electric Parts and Pair Hose
• 58

  Engine Sprocket and Gear Shift Lever
• 59

  Engine Mounting
• 61

  Engine Installation
• 67

  Engine Disassembly
• 67

  Starter Motor
• 67

  Cylinder Head Cover and Pair Reed Valve
• 68

  Camshafts
• 69

  Cylinder Head
• 72

  Oil Pump
• 72

  Gearshift System
• 73

  Starter Idle Gear
• 74

  Starter Clutch
• 74

  Cam Chain, Cam Chain Tensioner and Cam Chain Guide
• 74

  CKP Sensor
• 75

  Generator Cover
• 75

  Generator Rotor
• 75

  Water Pump
• 76

  Gear Position Switch
• 76

  Crankcase Breather (PCV) Cover
• 76

  Oil Filter
• 77

  Lower Crank Case
• 78

  Middle Crankcase
• 78

  Crankshaft
• 78

  Piston and Conrod
• 80

  Engine Components Inspection and Service
• 80

  Cylinder Head Cover
• 80

  CMP Sensor
• 80

  Pair Reed Valve
• 81

  PCV Hose
• 81

  Camshaft Identification
• 81

  Cam Wear
• 82

  Camshaft Journal Wear
• 83

  СAmshaft Runout
• 83

  СAm Sprocket
• 83

  СAm Chain Tension Adjuster
• 84

  СAm Chain Tensioner
• 84

  СAm Chain Guide
• 84

  СYlinder Head and Valve
• 84

  Valve and Valve Spring Disassembly
• 86

  Cylinder Head Distortion
• 86

  Valve Stem Runout
• 86

  Valve Head Radial Runout
• 87

  Valve Stem and Valve Face Wear Condition
• 87

  Valve Stem Deflection
• 87

  Valve Stem Wear
• 88

  Valve Guide Servicing
• 89

  Valve Seat Width Inspection
• 90

  Valve Seat Servicing
• 90

  Initial Seat Cut
• 91

  Top Narrowing Cut
• 91

  Bottom Narrowing Cut
• 92

  Final Seat Cut
• 93

  Valve Spring
• 94

  Valve and Valve Spring Reassembly
• 95

  Intake Pipe
• 96

  Water Bypass Union
• 96

  Clutch Drive Plates Inspection
• 97

  Clutch Spring Inspection
• 97

  Clutch Bearing Inspection
• 97

  Clutch Sleeve Hub/Primary Driven Gear Assembly
• 98

  Generator
• 99

  Gearshift Shaft/Gearshift Arm Disassembly
• 99

  Gearshift Shaft/Gearshift Arm Inspection
• 99

  Gearshift Shaft/Gearshift Arm Reassembly
• 100

  Oil Pressure Regulator
• 101

  Transmission
• 101

  Disassembly
• 102

  Reassembly
• 103

  Transmission Parts Location
• 104

  Cylinder Distortion
• 104

  Cylinder Bore
• 105

  Piston and Piston Ring
• 105

  Piston Diameter
• 105

  Piston-To-Cylinder Clearance
• 105

  Piston Pin and Pin Bore
• 106

  Piston Ring-To-Groove Clearance
• 106

  Piston Ring Free End Gap and Piston Ring End Gap
• 107

  Crankcase
• 107

  Gearshift Fork and Gearshift Cam
• 107

  Gearshift Fork-To-Groove Clearance
• 107

  Gearshift Fork Groove Width
• 108

  Gearshift Fork Thickness
• 108

  Gearshift Cam Bearing and Gearshift Shaft Bearing
• 108

  Bearing Inspection
• 108

  Bearing Removal
• 109

  Installation
• 111

  Oil Jet
• 111

  Inspection and Cleaning
• 112

  Plug
• 113

  Conrod Big End Side Clearance
• 113

  Conrod-Big End Bearing Inspection
• 113

  Conrod-Big End Bearing Selection
• 114

  Crankshaft and Conrod
• 114

  Crankshaft Runout
• 114

  Conrod Small End I.D.
• 115

  Crank Pin O.D.
• 115

  Bearing Thickness
• 116

  Bearing Selection Table
• 116

  Conrod I.D.
• 118

  Crankshaft Journal Bearing
• 118

  Selection
• 119

  Crankcase I.D. Specification
• 120

  Crankshaft Journal O.D. Specification
• 120

  Bearing Thickness Specification
• 121

  Crankshaft Thrust Bearing
• 121

  Crankshaft Thrust Clearance Adjustment
• 122

  Thrust Bearing Selection Table
• 123

  Engine Reassembly
• 123

  Piston Ring
• 133

  Oil Strainer
• 133

  Oil Pan
• 134

  Oil Pressure Switch
• 135

  Crankcase Breather Cover
• 138

  Cam Chain Drive Sprocket
• 138

  Cam Chain Tensioner and Cam Chain Guide
• 146

  Clutch Cover
• 149

  Camshaft
• 152

  Cam Chain Tension Adjuster
• 157

  FI System Diagnosis
• 159

  Precautions in Servicing
• 159

  Electrical Parts
• 159

  Connector/Coupler
• 160

  Fuse
• 160

  ECM/Various Sensors
• 162

  Electrical Circuit Inspection Procedure
• 162

  Open Circuit Check
• 163

  Continuity Check
• 163

  Voltage Check
• 164

  Short Circuit Check (Wire Harness to Ground)
• 165

  Using the Multi-Circuit Tester
• 165

  Using the Tester
• 166

  FI System Technical Features
• 166

  Injection Time (Injection Volume)
• 167

  Compensation of Injection Time (Volume)
• 167

  Injection Stop Control
• 168

  Injection Timing
• 169

  FI System Parts Location
• 171

  FI System Wiring Diagram
• 172

  Self-Diagnosis Function
• 172

  User Mode
• 173

  Dealer Mode
• 175

  TPS Adjustment
• 176

  Fail-Safe Function
• 178

  FI System Troubleshooting
• 180

  Self-Diagnostic Procedures
• 180

  Self-Diagnosis Reset Procedure
• 181

  Malfunction Code and Defective Condition
• 183

  'C11' CMP Sensor Circuit Malfunction
• 185

  'C12' CKP Sensor Circuit Malfunction
• 187

  'C13' IAP Sensor Circuit Malfunction
• 190

  'C14' TP Sensor Circuit Malfunction
• 191

  'C15' ECT Sensor Circuit Malfunction
• 193

  Output Voltage
• 195

  'C21' IAT Sensor Circuit Malfunction
• 197

  'C22' AP Sensor Circuit Malfunction
• 200

  'C23' to Sensor Circuit Malfunction
• 202

  'C28' STV Actuator Circuit Malfunction
• 204

  'C29' STP Sensor Circuit Malfunction
• 207

  'C31' GP Switch Circuit Malfunction
• 208

  'C32', 'C33', 'C34' or 'C35' Fuel Injector Circuit Malfunction
• 210

  'C41' FP Relay Circuit Malfunction
• 210

  'C42' IG Switch Circuit Malfunction
• 211

  'C49' Pair Control Solenoid Valve Circuit Malfunction
• 213

  Sensors
• 216

  Fuel System and Throttle Body
• 217

  Fuel Delivery System
• 218

  Fuel System
• 218

  Fuel Tank Lift-Up
• 218

  Fuel Tank Removal
• 219

  Fuel Pressure Inspection
• 220

  Fuel Pump Inspection
• 220

  Fuel Discharge Amount Inspection
• 221

  Fuel Pump Relay Inspection
• 222

  Fuel Pump and Fuel Filter Removal
• 222

  Construction
• 224

  Fuel Mesh Filter Inspection and Cleaning
• 224

  Fuel Pump and Fuel Mesh Filter Installation
• 228

  Throttle Body Construction
• 229

  Air Cleaner Box Removal
• 230

  Throttle Body Removal
• 231

  Throttle Body Disassembly
• 233

  Throttle Body Cleaning
• 234

  Throttle Body Reassembly
• 236

  Throttle Body Installation
• 237

  Air Cleaner Box Installation
• 237

  STP Sensor Adjustment
• 238

  Fuel Injector Removal
• 238

  Fuel Injector Inspection
• 238

  Fuel Injector Installation
• 239

  Fast Idle Adjustment
• 241

  Use for Digital Vacuum Tester
• 242

  Use for Vacuum Balancer Gauge
• 242

  Calibrating Each Vacuum Gauge
• 244

  Throttle Position Sensor (TPS) Setting
• 246

  Exhaust System
• 247

  Precautions for Exhaust System
• 247

  Exhaust System Components
• 250

  Cooling and Lubrication System
• 252

  Cooling Circuit Inspection
• 253

  Radiator and Water Hoses
• 253

  Radiator Removal
• 253

  Radiator Cap Inspection
• 253

  Radiator Inspection and Cleaning
• 254

  Water Hose Inspection
• 255

  Cooling Fan

Well, not sure about code but.its called Orange/Black orTangerine/Black.

hope this helped u!

How much does it cost to paint a 1000 square foot house?

It costs between $1000 - $3000 to paint a 1000 square foot house.

2001 gsxr 1000 top speed?

the top speed of a 2001 suzuki gsxr 1000 is 186 mph

Is there a difference between 2007 and 2008 suzuki gsxr 1000?

it's just the decals i mean just the colors and Suzuki logo's

Why is lava different colors?

Different colors of lava depends on its temperature, it starts out bright orange (1000-1150 C) then it cools the color changes to bright red (800-1000 C), then do dark red (650-800 C) and then the color is brownish red (500-650 C). The solid colored lava is black (but can still be very hot).

How much cement paint is needed to paint 1000 sq feet wall?

Need more info. Would need to know how many square feet one container of cement paint can cover. For example, if one container could paint 100 square feet, you would need 10 containers of paint: 1000/100=10

Does the 2008 Suzuki GSXR 1000 have a fuel filter if so where is it located?

If you have a stock fuel pump on your GSXR 1000 K8 your bike will NOT have a fuel filter.

How much does it cost to paint the hood of your car?

A professional paint job for a hood will generally run between $600-1000.

A tube of watercolor paint contains 250 milliliters of paint How many liters of paint are in the tube?

.25 Liters Because there are 1000ml in a liter and 250/1000 is .25

How many paint balls will you need to purchase for a whole days paint balling.?

Depends how much you shoot. 1000 is a safe estimate.

Why does your suzuki 1000 Alto car knock?

Cause they are junk? Next time go with GM or Chrysler

What is the best bike for a tall rider?

Suzuki V-strom, 650 or 1000. You can purchase a taller seat right from Suzuki, put on a set of bar risers and can even lower the pegs if needed.

Suzuki Gsx R1000

What year is the V storm model of Suzuki from?

There are two diferent types the V strom models of the Suzuki and they came from two different years. The newest one is the 650, its from 2004, and the 1000 is from 2002.

What is the freezing point of Fanta?

the freezing point of fanta orange is 1000 degrease

What color is a 1000 euro note?

It has this colour: because there are no €1000 notes. The highest denomination is €500.

How much do baseball players get paid when they drink Gatorade at the All-Star events?

Roxy music full album download. depends on the color red-10$ blue-10$ orange or yellow-10$ aqua marine blueish greenish poweraidish pays 1000$

What kind of car did starsky and hutch drive in the 1970s?

They drove a 1975 Ford Gran Torino and the paint job was a after market and people wanted cars with the same paint job so ford, in 1976, started painting some of (1000) them the red and white color. They were also seen threw out the series as the 'bad guys' driving them.

How do you interpret the four colour bands in resistor?

First You need to identify four colors after that each color has some certain value look up the table- Black- 0 Brown- 1 Red- 2 Orange- 3 Yellow- 4 Green- 5 Blue- 6 Violet- 7 Gray- 8 White- 9 Golden-5% silver-10% no color-20% DETECTING VALUES FROM COLOR CODE mark the value of first color after THAN mark the value of second color(marking from left to right) and after that third color has value power of… Read More

How much does an American painted horse weigh?

An American Paint Horse is a breed that varies greatly in size and weight. The average Paint is around about 1000 lbs.

An orange weighed 525 grams how many kilograms would that be?

To change from grams to kilograms you must divide by 1000. So 525/1000 would be 0.525kg. To change back, just times by 1000: 0.525*1000 = 525g

How much should it cost to repaint a car?

For Example, repaint Honda Civic. It can cost anywhere from $239 to $10,000 depending on a number of factors. Quality of paint, clear coat, different colors/details, etc.If you want a decent paint job, one color, with a clear coat, I would guess your looking at anywhere from 500-1000. Check out Maaco or local paint/autoshops. Call around or Google it. Good luck

How much white paint is needed to paint a 1000 square foot building?

1000 square feet to paint? You can paint 400 feet squared with one gallon. so you need to know how high the wall is 8 feet high by 1000 feet 8x1000 = 8000 square feet divided by 400feet per a gallon = 20 gallons one coat. just x the amount of coats you want to do and your good to go. You realy need to measure each wall and go HxL divided by 400feet per… Read More

What is the price for a suzuki x90?

The Suzuki X-90 was manufactured and sold from 1995 to 1997. Since any available for purchase would be used, the price would vary depending on the mileage on the car and the condition of the car. The average price for a used Suzuki X-90, in good shape, is in the range of $1000 and up.

How much calories does orange chicken have?

It depends on how much you're having. If it's a plateful, the orange chicken has around 1000 calories. If it's a normal serving it has about 500.

How much paint to spray paint 1000 square feet?

Too many variables. -Depends on surface you are spraying onto, type of spray equipment you are using, what paint you use to spray, how much you thin it to spray, etc, etc