The 2003-2008 Suzuki GSXR600, GSXR750, GSXR1000 repair manual by Haynes, covers the following sportbike models:
Book Excerpt: 2003-2008 Suzuki GSXR600, GSXR750, GSXR1000 Repair Manual
- Suzuki GSXR600-K4 2004
- Suzuki GSXR600-K5 2005
- Suzuki GSXR750-K4 2004
- Suzuki GSXR750-K5 2005
- Suzuki GSXR1000-K3 2003
- Suzuki GSXR1000-K4 2004
- Suzuki GSXR1000-K5 2005
- Suzuki GSXR1000-K6 2006
- Suzuki GSXR1000-K7 2007
- Suzuki GSXR1000-K8 2008
ENGINE: GENERAL INFORMATION
The engine/transmission unit is a water-cooled, four cylinder inline design fitted transversely across the frame. The valves are operated by double overhead camshafts which are chain driven off the crankshaft.
ENGINE REMOVAL and INSTALLATION
The engine/transmission unit is constructed from aluminum alloy with the crankcase divided horizontally into three sections. On 1000cc models, a balancer shaft is gear-driven off the crankshaft.
The crankcase incorporates a wet sump, pressure-fed lubrication system which uses a gear driven, dual-rotor oil pump.
On 600cc and 750cc models, a crankcase-mounted oil cooler works in conjunction with the engine cooling system; on 1000 models, the oil cooler is of the radiator type.
Power from the crankshaft is transferred via a wet, multi-plate clutch to a six-speed, constant mesh transmission unit. Final drive to the wheels is by chain and sprockets.
WARNING: The engine is very heavy. Removal and installation should be carried out with the aid of at least one assistant; personal injury or damage could occur if the engine falls or is dropped.
If available, a hydraulic or mechanical floor jack should be used to support and lower or raise the engine.
Special Tool: A peg spanner is required to loosen and tighten the locknuts on the engine rear mounting bolt adjusters and, on 600 and 750 models, the adjusters themselves.
If the Suzuki service tool (part # 09940-14990) is not available, a suitable peg spanner will have to be obtained or fabricated (see Tool Tip on page 2-16).
- Support the bike in an upright position using an auxiliary stand. Work can be made easier by raising the machine to a suitable working height on a hydraulic ramp or a suitable platform.
Make sure the motorcycle is secure and will not topple over (see Tools and Workshop Tips in the Reference section).
- If the engine is dirty, particularly around its mountings, wash it thoroughly before starting any major dismantling work. This will make work much easier and rule out the possibility of dirt falling into some vital component.
- Remove the seats, the fairing and the fairing side panels (see Chapter 7).
- Disconnect the negative (-) lead from the battery (see Chapter 8).
- Drain the engine oil and the coolant (see Chapter 1).
Subject: 2003, 2004, 2005, 2006, 2007, 2008, Suzuki GSXR600, GSXR750, GSXR1000 service, maintenance, repair. ISBN-10: 1844258114 | ISBN-13: 9781844258116 | Haynes 4382