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Table of Contents
- 3. Group index
- 4. Supplements
- 5. Component parts and work to be done
- 6. Symbol
- 7. Abbreviations used in this manual
- 9. SAE-to-former SUZUKI term
- 11. Wire color
- 12. General information
- 13. Warning/Caution/Note
- 15. SUZUKI GSX-R1000K5 ('05-Model)
- 16. Fuel, oil and engine coolant recommendat...
- 17. Front fork oil
- 18. Braek-in Procedures
- 19. Information labels
- 20. Specifications
- 22. Periodic maintenance
- 23. Periodic maintenance schedule
- 24. Lubrication points
- 25. Maintenance and tune-up procedures
- 26. Spark plug
- 28. Valve clearance
- 31. Intake side
- 32. Exhaust side
- 33. Engine oil and oil filter
- 34. Exhaust control valve
- 35. Fuel line
- 36. Throttle valve synchronization
- 37. Clutch
- 38. Cooling system
- 39. Air bleeding the cooling circuit
- 40. Radiator hoses
- 41. Drive chain
- 43. Cleaning and lubricating
- 44. Brake
- 45. Brake pads
- 46. Brake pedal height
- 47. Front brake (Caliper side)
- 48. Tires
- 50. Exhaust pipe bolt and nut
- 51. Chassis bolts and nuts
- 53. Compression pressure check
- 54. Oil pressure check
- 55. SDS check
- 56. Data at 3000 r/min under no load
- 57. Data of intake negative pressure during ...
- 58. Engine
- 59. Engine components removable with engine ...
- 60. Engine removal and installation
- 66. Engine mounting
- 67. Engine installation
- 72. Engine disassembly
- 84. Engine components inspection and service
- 85. Camshaft
- 87. Cam chain tension adjuster
- 88. Cam chain tensioner
- 100. Clutch
- 101. Clutch driven plate inspection
- 102. Clutch lifter
- 103. Oil pump
- 104. Starter clutch
- 105. Gearshift system
- 106. Oil pressure regulator
- 107. Transmission
- 109. Transmission parts location
- 110. Cylinder
- 111. Piston and piston ring
- 112. Piston ring-to-groove clearance
- 113. Crankcase
- 114. Gearshift fork thickness
- 117. Oil jet
- 118. Plug
- 120. Balancer shaft
- 122. Crankshaft and conrod
- 123. Conrod big end side clearance
- 125. Crank pin O.D.
- 126. Crankshaft journal bearing
- 127. Bearing selection table
- 128. Crankshaft journal O.D. specification
- 129. Crankshaft thrust bearing
- 130. Thrust bearing selection table
- 131. Engine reassembly
- 132. Piston and conrod
- 164. FI system diagnosis
- 166. Precautions in servicing
- 167. Fuse
- 169. Electrical circuit inspection procedure
- 170. Continuity check
- 171. Short circuit check (wire harness to gro...
- 172. Using the multi-circuit tester
- 173. FI system technical features
- 174. Compensation of injection time (volume)
- 175. FI system parts location
- 177. FI system wiring diagram
- 178. ECM terminal
- 180. Self-diagnosis function
- 181. Dealer mode
- 183. TPS adjustment
- 184. Fail-safe function
- 186. FI system troubleshooting
- 187. Visual inspection
- 188. Self-diagnosis procedures
- 189. Use of SDS diagnostic procedures
- 190. Use of SDS diagnosis reset procedure
- 191. Show data when trouble (Displaing data a...
- 192. Malfunction code and defective condition
- 196. "C11" (P0340) CMP sensor circuit malfunc...
- 198. "C12" (P0335) CKP sensor circuit malfunc...
- 200. "C13" (P0105-H/L) IAP sensor circuit mal...
- 206. "C14" (P0120-H/L) TP sensor circuit malf...
- 211. "C15" (P0115-H/L) ECT sensor circuit mal...
- 215. "C21" (P0110-H/L) IAT sensor circuit mal...
- 219. "C22" (P1450-H/L) AP sensor circuit malf...
- 224. "C23" (P1651-H/L) TO sensor circuit malf...
- 228. "C28" (P1655) STV actuator circuit malfu...
- 230. Active control inspection
- 231. "C29" (P1654-H/L) STP sensor circuit mal...
- 236. "C31" (P0705) GP switch circuit malfunct...
- 238. "C32" (P0201), "C33" (P0202), "C34" (P02...
- 240. "C36" (P1764), "C37" (P1765), "C38" (P17...
- 242. "C41" (P0230-H/L) FP relay circuit malfu...
- 244. "C42" (P01650) IG switch circuit malfunc...
- 245. "C46" (P1657-H/L or P1658) EXCV actuator...
- 254. "C49" (P1656) pair control solenoid valv...
- 256. "C60" (P0480) cooling fan relay circuit ...
- 258. Sensors
- 262. Fuel system and throttle body
- 263. Fuel delivery system
- 264. Fuel system
- 265. Fuel tank installation
- 266. Fuel pump inspection
- 267. Fuel pump relay inspection
- 268. Fuel pump and fuel filter removal
- 270. Fuel mesh filter inspection and cleaning
- 273. Throttle body (Construction)
- 274. Air cleaner box removal
- 275. Throttle body removal
- 276. Throttle body disassembly
- 278. Throttle body cleaning
- 279. Throttle body reassembly
- 282. Throttle body installation
- 283. Air cleaner box installation
- 284. Fuel injector removal
- 285. Fast idle
- 287. Throttle valve synchronization
- 288. Use of vacuum balancer gauge
- 290. Throttle position sensor (TPS) setting
- 292. Exhaust system
- 293. Exhaust control system
- 294. Operation
- 295. EXCVA (Exhaust control valve actuator) a...
- 297. EXCVA installation
- 299. EXCV cable replacement
- 301. EXCVA adjustment
- 304. EXCV/Muffler removal
- 305. EXCV Inspection
- 308. Cooling and lubrication system
- 309. Engine coolant
- 310. Cooling circuit
- 311. Radiator and water hoses
- 312. Radiator installation
- 313. Cooling fan
- 314. Cooling fan relay inpection
- 316. Thermostat
- 318. Water pump
- 320. Mechanical seal
- 326. Engine lubrication system chart
- 327. Engine lubrication system
- 330. Chassis
- 332. Exterior parts
- 334. Screen
- 335. Body cowling
- 336. Ait intake pipe
- 337. Rear seat and seat tail cover
- 338. Front Wheel (Construction)
- 340. Axle shaft
- 342. Reassembly and installation
- 346. Front fork (Construction)
- 350. Inner and outer tubes
- 351. Oil seal and dust seal
- 352. Fork oil
- 353. Front fork inner rod lock nut
- 355. Suspension setting
- 357. Steering damper (Construction)
- 359. Steering (Construction)
- 363. Front fork and steering stem upper brack...
- 364. Steering tension adjustment
- 365. Handlebars (Construction)
- 369. Rear wheel (Construction)
- 373. Reassembly and installation
- 375. Wheel damper
- 376. Brake disc
- 377. Rear shock absorber (Construction)
- 379. Rear shock absorber disposal
- 380. Suspension setting
- 381. Rear suspension (Construction)
- 383. Swingarm pivot boss removal and installa...
- 385. Cushion lever bearing
- 386. Swingarm pivot shaft
- 387. Reassembly
- 389. Swingarm pivot thrust clearance adjustme...
- 390. Final inspection and adjustment
- 391. Front brake (Construction)
- 392. Brake pad replacement
- 393. Brake fluid replacement
- 394. Caliper removal
- 395. Caliper inspection
- 397. Brake disc inspection
- 398. Master cylinder removal and disassembly
- 399. Master cylinder inspection
- 400. Master cylinder reassembly
- 401. Master cylinder installation
- 402. Rear brake (Construction)
- 408. Master cylinder removal
- 411. Tire and wheel
- 412. Valve inspection
- 413. Tire installation
- 414. Balancer weight installation
- 415. Drive chain
- 416. Drive chain connecting
- 417. Joint pin staking
- 420. Electrical system
- 422. Cautions in servicing
- 425. Location of electrical components
- 427. Charging system
- 428. Battery overcharges
- 431. Starter system and side-stand/Ignition i...
- 432. Starter motor removal
- 433. Starter motor disassembly
- 435. Starter relay inspection
- 436. Side stand/Ignition interlock system par...
- 438. Turn signal/Side-stand relay
- 439. Ignition system
- 440. Immobilizer (Except for E-03, 28, 33)
- 442. No spark or poor spark
- 444. Ignition coil primary peak voltage
- 448. Combination meter
- 452. Fuel level indicator light inspection
- 454. Lamps
- 456. Relays
- 457. Ignition switch removal
- 458. Switches inspection
- 459. Battery specifications
- 461. Servicing
- 462. Servicing information
- 464. FI system malfunction code and defective...
- 468. Engine
- 474. Radiator (Cooling system)
- 475. Chassis
- 476. Brakes
- 477. Electrical
- 478. Battery
- 479. Wiring harness, cable and hose routing
- 482. Cable routing
- 483. Throttle body hose routing
- 484. Fuel tank drain hose routing
- 485. Cooling system hose routing
- 486. Front brake hose routing
- 487. Rear brake hose routing
- 488. Pair (air supply) system hose routing
- 489. Fuel tank installation
- 490. Fuel tank lower side cover cushion rubbe...
- 491. Cowling installation
- 492. Frame cover installation
- 493. Rear fender installation
- 494. Under cowling heat shield installation
- 495. Body cowling cover cushion installation
- 496. Headlight tape cushion installation
- 497. Side-stand installation
- 498. Handlebar balancer
- 499. Rear view mirror installation
- 500. Rear combinator light installation
- 501. Regulator/Rectifier installation
- 502. Special tools
- 506. Tightening torque
- 509. Tightening torque chart
- 510. Service data
- 511. Cylinder + Piston + Piston ring
- 512. Conrod + Crankshaft
- 513. Clutch
- 514. Thermostat + Radiator + Fan + Coolant
- 515. FI sensors
- 516. Throttle body
- 517. Wattage
- 518. Tire
- 519. Suspension
- 520. Emission control information
- 521. Emission control systems
- 522. Crankcase emission control system
- 523. Exhaust emission control system (Pair sy...
- 524. Noise emission control system
- 525. Pair (Air supply) system and emission co...
- 527. Pair (Air supply) system diagram
- 528. Pair (Air supply) system hose routing
- 530. Fuel-shut off valve
- 531. Evap canister hose routing (Only for E-3...
- 532. GSX-R1000K6
- 533. Specifications
- 534. Service data
- 536. Oil pump
- 540. Throttle body
- 544. Battery holder cushion rubber installati...
- 545. Wiring diagram E-02, 19, 24
- 546. E-03, 28, 33
Page 1 of 548
Table of Contents
- 3. Group index
- 4. Supplements
- 5. Component parts and work to be done
- 6. Symbol
- 7. Abbreviations used in this manual
- 9. SAE-to-former SUZUKI term
- 11. Wire color
- 12. General information
- 13. Warning/Caution/Note
- 15. SUZUKI GSX-R1000K5 ('05-Model)
- 16. Fuel, oil and engine coolant recommendat...
- 17. Front fork oil
- 18. Braek-in Procedures
- 19. Information labels
- 20. Specifications
- 22. Periodic maintenance
- 23. Periodic maintenance schedule
- 24. Lubrication points
- 25. Maintenance and tune-up procedures
- 26. Spark plug
- 28. Valve clearance
- 31. Intake side
- 32. Exhaust side
- 33. Engine oil and oil filter
- 34. Exhaust control valve
- 35. Fuel line
- 36. Throttle valve synchronization
- 37. Clutch
- 38. Cooling system
- 39. Air bleeding the cooling circuit
- 40. Radiator hoses
- 41. Drive chain
- 43. Cleaning and lubricating
- 44. Brake
- 45. Brake pads
- 46. Brake pedal height
- 47. Front brake (Caliper side)
- 48. Tires
- 50. Exhaust pipe bolt and nut
- 51. Chassis bolts and nuts
- 53. Compression pressure check
- 54. Oil pressure check
- 55. SDS check
- 56. Data at 3000 r/min under no load
- 57. Data of intake negative pressure during ...
- 58. Engine
- 59. Engine components removable with engine ...
- 60. Engine removal and installation
- 66. Engine mounting
- 67. Engine installation
- 72. Engine disassembly
- 84. Engine components inspection and service
- 85. Camshaft
- 87. Cam chain tension adjuster
- 88. Cam chain tensioner
- 100. Clutch
- 101. Clutch driven plate inspection
- 102. Clutch lifter
- 103. Oil pump
- 104. Starter clutch
- 105. Gearshift system
- 106. Oil pressure regulator
- 107. Transmission
- 109. Transmission parts location
- 110. Cylinder
- 111. Piston and piston ring
- 112. Piston ring-to-groove clearance
- 113. Crankcase
- 114. Gearshift fork thickness
- 117. Oil jet
- 118. Plug
- 120. Balancer shaft
- 122. Crankshaft and conrod
- 123. Conrod big end side clearance
- 125. Crank pin O.D.
- 126. Crankshaft journal bearing
- 127. Bearing selection table
- 128. Crankshaft journal O.D. specification
- 129. Crankshaft thrust bearing
- 130. Thrust bearing selection table
- 131. Engine reassembly
- 132. Piston and conrod
- 164. FI system diagnosis
- 166. Precautions in servicing
- 167. Fuse
- 169. Electrical circuit inspection procedure
- 170. Continuity check
- 171. Short circuit check (wire harness to gro...
- 172. Using the multi-circuit tester
- 173. FI system technical features
- 174. Compensation of injection time (volume)
- 175. FI system parts location
- 177. FI system wiring diagram
- 178. ECM terminal
- 180. Self-diagnosis function
- 181. Dealer mode
- 183. TPS adjustment
- 184. Fail-safe function
- 186. FI system troubleshooting
- 187. Visual inspection
- 188. Self-diagnosis procedures
- 189. Use of SDS diagnostic procedures
- 190. Use of SDS diagnosis reset procedure
- 191. Show data when trouble (Displaing data a...
- 192. Malfunction code and defective condition
- 196. "C11" (P0340) CMP sensor circuit malfunc...
- 198. "C12" (P0335) CKP sensor circuit malfunc...
- 200. "C13" (P0105-H/L) IAP sensor circuit mal...
- 206. "C14" (P0120-H/L) TP sensor circuit malf...
- 211. "C15" (P0115-H/L) ECT sensor circuit mal...
- 215. "C21" (P0110-H/L) IAT sensor circuit mal...
- 219. "C22" (P1450-H/L) AP sensor circuit malf...
- 224. "C23" (P1651-H/L) TO sensor circuit malf...
- 228. "C28" (P1655) STV actuator circuit malfu...
- 230. Active control inspection
- 231. "C29" (P1654-H/L) STP sensor circuit mal...
- 236. "C31" (P0705) GP switch circuit malfunct...
- 238. "C32" (P0201), "C33" (P0202), "C34" (P02...
- 240. "C36" (P1764), "C37" (P1765), "C38" (P17...
- 242. "C41" (P0230-H/L) FP relay circuit malfu...
- 244. "C42" (P01650) IG switch circuit malfunc...
- 245. "C46" (P1657-H/L or P1658) EXCV actuator...
- 254. "C49" (P1656) pair control solenoid valv...
- 256. "C60" (P0480) cooling fan relay circuit ...
- 258. Sensors
- 262. Fuel system and throttle body
- 263. Fuel delivery system
- 264. Fuel system
- 265. Fuel tank installation
- 266. Fuel pump inspection
- 267. Fuel pump relay inspection
- 268. Fuel pump and fuel filter removal
- 270. Fuel mesh filter inspection and cleaning
- 273. Throttle body (Construction)
- 274. Air cleaner box removal
- 275. Throttle body removal
- 276. Throttle body disassembly
- 278. Throttle body cleaning
- 279. Throttle body reassembly
- 282. Throttle body installation
- 283. Air cleaner box installation
- 284. Fuel injector removal
- 285. Fast idle
- 287. Throttle valve synchronization
- 288. Use of vacuum balancer gauge
- 290. Throttle position sensor (TPS) setting
- 292. Exhaust system
- 293. Exhaust control system
- 294. Operation
- 295. EXCVA (Exhaust control valve actuator) a...
- 297. EXCVA installation
- 299. EXCV cable replacement
- 301. EXCVA adjustment
- 304. EXCV/Muffler removal
- 305. EXCV Inspection
- 308. Cooling and lubrication system
- 309. Engine coolant
- 310. Cooling circuit
- 311. Radiator and water hoses
- 312. Radiator installation
- 313. Cooling fan
- 314. Cooling fan relay inpection
- 316. Thermostat
- 318. Water pump
- 320. Mechanical seal
- 326. Engine lubrication system chart
- 327. Engine lubrication system
- 330. Chassis
- 332. Exterior parts
- 334. Screen
- 335. Body cowling
- 336. Ait intake pipe
- 337. Rear seat and seat tail cover
- 338. Front Wheel (Construction)
- 340. Axle shaft
- 342. Reassembly and installation
- 346. Front fork (Construction)
- 350. Inner and outer tubes
- 351. Oil seal and dust seal
- 352. Fork oil
- 353. Front fork inner rod lock nut
- 355. Suspension setting
- 357. Steering damper (Construction)
- 359. Steering (Construction)
- 363. Front fork and steering stem upper brack...
- 364. Steering tension adjustment
- 365. Handlebars (Construction)
- 369. Rear wheel (Construction)
- 373. Reassembly and installation
- 375. Wheel damper
- 376. Brake disc
- 377. Rear shock absorber (Construction)
- 379. Rear shock absorber disposal
- 380. Suspension setting
- 381. Rear suspension (Construction)
- 383. Swingarm pivot boss removal and installa...
- 385. Cushion lever bearing
- 386. Swingarm pivot shaft
- 387. Reassembly
- 389. Swingarm pivot thrust clearance adjustme...
- 390. Final inspection and adjustment
- 391. Front brake (Construction)
- 392. Brake pad replacement
- 393. Brake fluid replacement
- 394. Caliper removal
- 395. Caliper inspection
- 397. Brake disc inspection
- 398. Master cylinder removal and disassembly
- 399. Master cylinder inspection
- 400. Master cylinder reassembly
- 401. Master cylinder installation
- 402. Rear brake (Construction)
- 408. Master cylinder removal
- 411. Tire and wheel
- 412. Valve inspection
- 413. Tire installation
- 414. Balancer weight installation
- 415. Drive chain
- 416. Drive chain connecting
- 417. Joint pin staking
- 420. Electrical system
- 422. Cautions in servicing
- 425. Location of electrical components
- 427. Charging system
- 428. Battery overcharges
- 431. Starter system and side-stand/Ignition i...
- 432. Starter motor removal
- 433. Starter motor disassembly
- 435. Starter relay inspection
- 436. Side stand/Ignition interlock system par...
- 438. Turn signal/Side-stand relay
- 439. Ignition system
- 440. Immobilizer (Except for E-03, 28, 33)
- 442. No spark or poor spark
- 444. Ignition coil primary peak voltage
- 448. Combination meter
- 452. Fuel level indicator light inspection
- 454. Lamps
- 456. Relays
- 457. Ignition switch removal
- 458. Switches inspection
- 459. Battery specifications
- 461. Servicing
- 462. Servicing information
- 464. FI system malfunction code and defective...
- 468. Engine
- 474. Radiator (Cooling system)
- 475. Chassis
- 476. Brakes
- 477. Electrical
- 478. Battery
- 479. Wiring harness, cable and hose routing
- 482. Cable routing
- 483. Throttle body hose routing
- 484. Fuel tank drain hose routing
- 485. Cooling system hose routing
- 486. Front brake hose routing
- 487. Rear brake hose routing
- 488. Pair (air supply) system hose routing
- 489. Fuel tank installation
- 490. Fuel tank lower side cover cushion rubbe...
- 491. Cowling installation
- 492. Frame cover installation
- 493. Rear fender installation
- 494. Under cowling heat shield installation
- 495. Body cowling cover cushion installation
- 496. Headlight tape cushion installation
- 497. Side-stand installation
- 498. Handlebar balancer
- 499. Rear view mirror installation
- 500. Rear combinator light installation
- 501. Regulator/Rectifier installation
- 502. Special tools
- 506. Tightening torque
- 509. Tightening torque chart
- 510. Service data
- 511. Cylinder + Piston + Piston ring
- 512. Conrod + Crankshaft
- 513. Clutch
- 514. Thermostat + Radiator + Fan + Coolant
- 515. FI sensors
- 516. Throttle body
- 517. Wattage
- 518. Tire
- 519. Suspension
- 520. Emission control information
- 521. Emission control systems
- 522. Crankcase emission control system
- 523. Exhaust emission control system (Pair sy...
- 524. Noise emission control system
- 525. Pair (Air supply) system and emission co...
- 527. Pair (Air supply) system diagram
- 528. Pair (Air supply) system hose routing
- 530. Fuel-shut off valve
- 531. Evap canister hose routing (Only for E-3...
- 532. GSX-R1000K6
- 533. Specifications
- 534. Service data
- 536. Oil pump
- 540. Throttle body
- 544. Battery holder cushion rubber installati...
- 545. Wiring diagram E-02, 19, 24
- 546. E-03, 28, 33
File size: 17.03 MB
Created: March 11, 2023
Last updated: April 04, 2023
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