GSXS1000 service data

GSXS1000 Service Data

GSXS1000 Service Data

GSXS1000 Service Data, engine, chassis and electrical data necessary for successful maintenance and servicing of your Suzuki GSX-s 1000

GSXS-1000 Service Data

Emission Control Devices

Item Specification Standard Limit
EVAP system purge control solenoid valve power supply voltage (If equipped)    Battery voltage   
EVAP system purge control solenoid valve resistance (If equipped) 20 °C (68 °F) 30 – 34 Ω   
PAIR control solenoid valve power supply voltage    Battery voltage   
PAIR control solenoid valve resistance 20 – 30 °C (68 – 86 °F) 20 – 24 Ω   

Engine Electrical Devices

Item Specification Standard Limit
AP sensor power supply voltage   4.75 – 5.25 V
AP sensor output voltage Idle speed at 1 atm. Approx. 2.8 V
IAP sensor power supply voltage   4.75 – 5.25 V
IAP sensor output voltage Idle speed at 1 atm. Approx. 2.7 V
IAT sensor power supply voltage    4.5 – 5.5 V
IAT sensor output voltage    0.15 – 4.85 V
IAT sensor resistance 0 °C (32 °F) 5400 – 6600 Ω
80 °C (176 °F) 290 – 390 Ω
ECT sensor power supply voltage    4.5 – 5.5 V
ECT sensor resistance –20 °C (–4 °F) 13840 –16330 Ω
20 °C (68 °F) 2320 – 2590 Ω
80 °C (176 °F) 310 – 326 Ω
TP sensor power supply voltage    4.5 – 5.5 V
TP sensor output voltage Closed 1.10 – 1.14 V
Opened Approx. 4.5 V
STP sensor power supply voltage    4.5 – 5.5 V
STP sensor output voltage Closed 0.57 – 0.67 V
Opened Approx. 4.5 V
ISC valve resistance 20 °C (68 °F) Approx. 20 Ω
HO2 sensor output voltage Idle speed 0.6 V or less
5000 r/min 0.6 V or more
HO2 sensor heater power supply voltage    Battery voltage
HO2 sensor heater resistance 23 °C (73.4 °F) 11.5 – 17.5 Ω
CKP sensor peak voltage When cranking 0.5 V or more
CKP sensor resistance 20 °C (68 °F) Approx. 168 Ω
TO sensor power supply voltage    4.5 – 5.5 V
TO sensor output voltage Normal 0.4 – 1.4 V
Leaning 65° 3.7 – 4.4 V
TO sensor resistance    16500 – 22300 Ω
ECM power supply voltage    Battery voltage

Engine Mechanical

Item Specification Standard Limit
Throttle body I.D. No. For Thailand, Taiwan, Vietnam, China and California State 04K1
Except for Thailand, Taiwan, Vietnam, China and California State 04K0
Throttle body bore size    44 mm (1.7 in)
Throttle cable play    2.0 – 4.0 mm (0.079 – 0.157 in)
Idle speed When engine warmed 1150 ± 100 r/min
Fast idle speed    1150 – 2000 r/min
STVA resistance    Approx. 7.8 Ω
Compression pressure    1300 – 1700 kPa 1000 kPa
(13.3 – 17.3 kgf/cm2, 188 – 246 psi) (10.2 kgf/cm2,
  145 psi)
Compression pressure difference    200 kPa (2 kgf/cm2, 28 psi)
Cam height Intake 36.78 – 36.83 mm 36.48 mm
(1.448 – 1.450 in) (1.437 in)
Exhaust 36.63 – 36.68 mm 36.33 mm
(1.443 – 1.444 in) (1.431 in)
Camshaft journal oil clearance Intake 0.032 – 0.066 mm 0.150 mm (0.0059 in)
(0.0013 – 0.0025 in)
Exhaust 0.032 – 0.066 mm 0.150 mm (0.0059 in)
(0.0013 – 0.0025 in)
Camshaft journal holder I.D. Intake 24.012 – 24.025 mm
(0.9454 – 0.9458 in)
Exhaust 24.012 – 24.025 mm
(0.9454 – 0.9458 in)
Camshaft journal O.D. Intake 23.959 – 23.980 mm
(0.9433 – 0.9440 in)
Exhaust 23.959 – 23.980 mm
(0.9433 – 0.9440 in)
Camshaft runout Intake & Exhaust 0.10 mm
(0.004 in)
Cam chain pin At arrow “3” 14th pin
Valve clearance When engine cold Intake 0.10 – 0.20 mm
(0.0040 – 0.0078 in)
Exhaust 0.20 – 0.30 mm
(0.0079 – 0.0118 in)
Valve diameter Intake 30 mm (1.2 in)
Exhaust 24 mm (0.94 in)
Valve stem runout Intake & Exhaust 0.05 mm (0.0019 in)
Valve head radial runout Intake & Exhaust 0.03 mm (0.0011 in)
Valve head thickness Intake 0.5 mm
(0.019 in)
Exhaust 0.5 mm
(0.019 in)
Valve stem O.D. Intake 4.475 – 4.490 mm
(0.1762 – 0.1767 in)
Exhaust 4.455 – 4.470 mm
(0.1754 – 0.1759 in)
Valve seat width Intake 0.9 – 1.1 mm
(0.036 – 0.043 in)
Exhaust 0.9 – 1.1 mm
(0.036 – 0.043 in)
Valve guide I.D. Intake 4.500 – 4.512 mm
(0.1772 – 0.1776 in)
Exhaust 4.500 – 4.512 mm
(0.1772 – 0.1776 in)
Valve guide to valve stem clearance Intake 0.010 – 0.037 mm
(0.0004 – 0.0014 in)
Exhaust 0.030 – 0.057 mm
(0.0012 – 0.0022 in)
Valve spring free length Intake 37.3 mm
(1.47 in)
Exhaust 37.3 mm
(1.47 in)
Valve spring pre-load When compressed to Intake 141 – 163 N
33.55 mm (1.321 in) (14.4 – 16.6 kgf, 31.7 – 36.6 lbs)
  Exhaust 141 – 163 N
  (14.4 – 16.6 kgf, 31.7 – 36.6 lbs)
Cylinder head distortion    0.20 mm
(0.0078 in)
Cylinder distortion    0.20 mm
(0.0078 in)
Cylinder bore    73.400 – 73.415 mm No nicks or Scratches
(2.8898 – 2.8903 in)
Piston diameter Measure at 8 mm (0.3 in) from the skirt end. 73.370 – 73.385 mm 73.280 mm
(2.8886 – 2.8891 in) (2.8851 in)
Piston to cylinder clearance    0.025 – 0.035 mm 0.120 mm
(0.0010 – 0.0013 in) (0.0047 in)
Piston ring to groove clearance 1st 0.180 mm
(0.0070 in)
2nd 0.150 mm
(0.0059 in)
Piston ring groove width 1st 0.81 – 0.83 mm
(0.0319 – 0.0326 in)
2nd 0.81 – 0.83 mm
(0.0319 – 0.0326 in)
Oil 1.51 – 1.53 mm
(0.0595 – 0.0602 in)
Piston ring thickness 1st 0.77 – 0.79 mm
(0.0304 – 0.0311 in)
2nd 0.77 – 0.79 mm
(0.0304 – 0.0311 in)
Piston ring free end gap 1st Approx. 9 mm 7.2 mm
(0.4 in) (0.29 in)
2nd Approx. 8 mm 6.4 mm
(0.3 in) (0.26 in)
Piston ring end gap 1st 0.06 – 0.18 mm 0.50 mm
(0.0024 – 0.0070 in) (0.019 in)
2nd 0.06 – 0.18 mm 0.50 mm
(0.0024 – 0.0070 in) (0.019 in)
Piston pin bore I.D.    16.002 – 16.008 mm 16.030 mm
(0.6300 – 0.6302 in) (0.6311 in)
Piston pin O.D.    15.995 – 16.000 mm 15.980 mm
(0.6298 – 0.6299 in) (0.6292 in)
Conrod small end I.D.    16.010 – 16.018 mm 16.040 mm
(0.6304 –0.6306 in) (0.6314 in)
Conrod big end side clearance    0.10 – 0.20 mm 0.3 mm
(0.0040 – 0.0078 in) (0.011 in)
Conrod big end width    19.95 – 20.00 mm
(0.7855 – 0.7874 in)
Conrod big end I.D.    38.000 – 38.016 mm
(1.4961 – 1.4966 in)
Conrod big end oil clearance    0.040 – 0.064 mm 0.080 mm (0.0031 in)
(0.0016 – 0.0025 in)
Crank pin width    20.10 – 20.15 mm
(0.7914 – 0.7933 in)
Crank pin O.D.    34.976 – 35.000 mm
(1.3770 – 1.3779 in)
Crank pin bearing thickness    1.476 – 1.492 mm
(0.0582 – 0.0587 in)
Crankshaft journal O.D.    34.982 – 35.000 mm
(1.3773 – 1.3779 in)
Crankshaft journal oil clearance    0.010 – 0.028 mm 0.080 mm (0.0031 in)
(0.0004 – 0.0011 in)
Crankcase journal I.D.    38.000 – 38.018 mm
(1.4961 – 1.4967 in)
Crankcase journal bearing thickness    1.492 – 1.507 mm
(0.0588 – 0.0593 in)
Crankshaft thrust bearing thickness Right side 2.42 – 2.44 mm
(0.0953 – 0.0960 in)
Left side 2.36 – 2.50 mm
(0.0930 – 0.0984 in)
Crankshaft thrust clearance    0.060 – 0.110 mm
(0.0024 – 0.0043 in)
Crankshaft runout    0.05 mm
(0.0019 in)
Balancer journal oil clearance    0.028 – 0.052 mm 0.080 mm (0.0031 in)
(0.0011 – 0.0020 in)
Balancer journal O.D.    22.976 – 22.992 mm
(0.9046 – 0.9051 in)

Engine Lubrication System

Item Specification Standard Limit
Oil pressure At 60 °C (140 °F), 100 – 400 kPa
3000 r/min (1.0 – 4.1 kgf/cm2, 14.5 – 58.0 psi)
Necessary amount of engine oil Oil change 2800 ml (3.0 US qt, 2.5 Imp qt)
Oil and filter change 3200 ml (3.4 US qt, 2.8 Imp qt)
Engine overhaul 3400 ml (3.6 US qt, 3.0 Imp qt)
Cooling System
Item Specification Standard Limit
Engine coolant Engine side Approx. 2500 ml
(5.28 US qt, 4.40 Imp qt)
Reservoir tank side Approx. 250 ml
(0.53 US qt, 0.44 Imp qt)
Radiator cap valve opening pressure    107.9 – 137.3 kPa
(1.1 – 1.4 kgf/cm2, 15.7 – 19.9 psi)
Cooling fan relay power supply voltage    Battery voltage
Cooling fan operating temperature OFF → ON Approx. 105 °C
(221 °F)
ON → OFF Approx. 100 °C
(212 °F)
Thermostat valve opening temperature    Approx. 82 °C
(179.6 °F)
Thermostat valve lift 95 °C (203 °F) 8 mm (0.3 in) or more

Fuel System

Item Specification Standard Limit
Fuel injector power supply voltage    Battery voltage   
Fuel injector resistance 20 °C (68 °F) 11.5 – 12.5 Ω
FP relay power supply voltage    Battery voltage
FP discharge amount Per 10 seconds 223 ml
(7.55 US oz, 7.85 Imp oz) or more
Fuel pressure regulator operating set pressure    289 – 299 kPa
(2.95 – 3.04 kgf/cm2, 42.0 – 43.3 psi)

Ignition System

Item Specification Standard Limit
Firing order    1·2·4·3
Spark plug Type NGK: CR9EIA-9 / DENSO: IU27D
Gap 0.8 – 0.9 mm (0.032 – 0.035 in)
Spark performance At 1 atm 8 mm (0.3 in) or more
Ignition coil primary peak voltage    80 V or more
Ignition coil resistance Primary 10 – 30 °C 1.1 – 1.9 Ω
(50 – 86 °F)
Secondary 6400 – 9600 Ω
Immobilizer antenna power supply voltage (If equipped)    Battery voltage

Starting System

Item Specification Standard Limit
Starter motor brush length    12 mm (0.47 in) 8.5 mm
(0.33 in)
Starter relay resistance    3 – 6 Ω
Side-stand switch voltage ON (Side-stand retracted) 0.4 – 0.6 V
OFF (Side-stand on the ground) 1.4 V or more

Charging System

Item Specification Standard Limit
Battery leakage current    3 mA or less
Regulated voltage Charging output At 5000 r/min 14.0 – 15.5 V
Generator coil resistance 20 °C (68 °F) 0.12 – 0.18 Ω
Generator no-load voltage When engine cold At 5000 r/min 65 V (AC) or more
Recharging time Standard charging 1.2 A for 5 to 10 hours
Fast charging 5 A for 1 hour
Generator Max. output At 5000 r/min Approx. 385 W
Battery Type designation FT12A-BS
Capacity 12 V 36.0 kC (10Ah)/10 HR

Exhaust System

Item Specification Standard Limit
EXCVA position sensor power supply voltage    4.5 – 5.5 V
EXCVA position sensor output voltage Closed 0.45 – 1.40 V
Opened 3.60 – 4.55 V
EXCVA position sensor resistance At adjustment position Approx. 3100 Ω

Front Suspension

Item Specification Standard Limit
Front fork inner tube O.D.    43 mm (1.7 in)
Front fork oil level Without spring, outer tube fully compressed GSX-S1000/A 95 mm (3.7 in)
GSX-S1000F/FA 91 mm (3.6 in)
Front fork spring free length    271.1 mm (10.67 in) 265 mm
(10.5 in)
Front fork oil capacity Each leg GSX-S1000/A 518 ml
(17.52 US oz, 18.23 Imp oz)
GSX-S1000F/FA 523 ml
(17.68 US oz, 18.41 Imp oz)
Front fork spring adjuster    10 mm (0.39 in)
Front fork damping force adjuster Rebound side 8 clicks counterclockwise from stiffest position
Compression side 8 clicks counterclockwise from stiffest position

Rear Suspension

Item Specification Standard Limit
Rear shock absorber spring adjuster GSX-S1000/A 4th position
GSX-S1000F/FA 3rd position
Rear shock absorber damping force adjuster Rebound side 1 turn counterclockwise from stiffest position
Swingarm pivot shaft runout    0.3 mm
(0.011 in)

Wheels and Tires

Item Specification Standard Limit
Wheel rim runout Front Axial & Radial 2.0 mm
(0.08 in)
Rear Axial & Radial 2.0 mm
(0.08 in)
Wheel axle runout Front 0.25 mm (0.010 in)
Rear 0.25 mm (0.010 in)
Tire size Front 120/70ZR17M/C (58W)
Rear 190/50ZR17M/C (73W)
Tire type Front DUNLOP/D214F M
Rear DUNLOP/D214 M
Tire tread depth (Recommended depth) Front 1.6 mm
(0.062 in)
Rear 2.0 mm
(0.078 in)
Cold inflation tire pressure Solo riding Front 250 kPa (2.50 kgf/cm2, 36 psi)
Rear 290 kPa (2.90 kgf/cm2, 42 psi)
Dual riding Front 250 kPa (2.50 kgf/cm2, 36 psi)
Rear 290 kPa (2.90 kgf/cm2, 42 psi)
Wheel rim size Front 17 M/C x MT 3.50
Rear 17 M/C x MT 6.00

Drive Chain / Drive Train / Drive Shaft

Item Specification Standard Limit
Drive chain Type RK525GSH
Links 116 links
Drive chain 20-pitch length    319.4 mm
(12.57 in)
Drive chain slack On side-stand 20 – 30 mm
(0.79 – 1.18 in)

Brake Control System and Diagnosis

Item Specification Standard Limit
Rear brake pedal height    50 – 60 mm (2.0 – 2.3 in)
Master cylinder bore / piston diameter Front Approx. 19.1 mm (0.752 in)
Rear Approx. 14.0 mm (0.551 in)

Front Brakes

Item Specification Standard Limit
Front brake disc thickness    5.0 mm (0.20 in) 4.5 mm
(0.18 in)
Front brake disc runout    0.30 mm (0.012 in)
Front brake caliper cylinder bore / piston diameter    Approx. 32 mm (1.3 in)

Rear Brakes

Item Specification Standard Limit
Rear brake disc thickness    5.0 mm (0.20 in) 4.5 mm
(0.18 in)
Rear brake disc runout    0.30 mm (0.012 in)
Rear brake caliper cylinder bore / piston diameter    Approx. 38.2 mm (1.50 in)

ABS

Item Specification Standard Limit
Wheel speed sensor – sensor rotor clearance Front 0.38 – 1.05 mm
(0.0150 – 0.0413 in)
Rear 0.42 – 1.08 mm
(0.0166 – 0.0425 in)

Manual Transmission

Item Specification Standard Limit
Gearshift fork to groove clearance No.1 0.1 – 0.3 mm (0.004 – 0.011 in) 0.5 mm
(0.019 in)
No.3 0.1 – 0.3 mm (0.004 – 0.011 in) 0.5 mm
(0.019 in)
Gearshift fork groove width No.1 5.0 – 5.1 mm (0.197 – 0.200 in)
No.3 5.0 – 5.1 mm (0.197 – 0.200 in)
Gearshift fork thickness No.1 4.8 – 4.9 mm (0.189 – 0.192 in)
No.3 4.8 – 4.9 mm (0.189 – 0.192 in)
Gearshift lever height    45 – 55 mm (1.8 – 2.1 in)
GP switch power supply voltage    4.5 – 5.5 V
GP switch voltage From 1st to Top 0.6 V or more

Clutch

Item Specification Standard Limit
Clutch lever play    10 – 15 mm
(0.4 – 0.6 in)
Clutch release screw    1/2 turn counterclockwise
Drive plate thickness    2.72 – 2.88 mm 2.42 mm (0.0953 in)
(0.107 – 0.113 in)
Drive plate claw width    13.85 – 13.96 mm 13.35 mm (0.5256 in)
(0.5453 – 0.5496 in)
Driven plate distortion    0.10 mm (0.0039 in)
Clutch spring free length    66.7 mm (2.63 in) 63.4 mm
(2.50 in)

Steering / Handlebar

Item Specification Standard Limit
Steering tension initial force    2 – 5 N
(0.21 – 0.50 kgf, 0.50 – 1.12 lbf)

Wiring Systems

Item Specification Standard Limit
Fuse size Headlight HI 10 A
LO 10 A
Ignition 10 A
Signal 10 A
Fuel 10 A
Fan 15 A
Main 30 A
ABS motor (If equipped) 20 A
ABS valve (If equipped) 15 A

Lighting Systems

Item Specification Standard Limit
Headlight GSX-S1000/A 12 V 60/55 W (H4)
GSX-S1000F/FA HI 12 V 55 W (H7)
LO 12 V 55 W (H7)
Position light (If equipped)    LED
Brake light/Taillight    LED
Turn signal light    12 V 21 W × 4
License plate light    12 V 5 W

Combination Meter / Fuel Meter / Horn

Item Specification Standard Limit
Speed sensor power supply voltage (Without ABS) Front Battery voltage
Rear Battery voltage
Instrument panel light    LED
Turn signal indicator light    LED × 2
High beam indicator light    LED
Neutral indicator light    LED
Oil pressure indicator light/Engine coolant temp. indicator light    LED
MIL    LED
Traction control system indicator light    LED
ABS indicator light (If equipped)    LED
Immobilizer indicator light    LED
(If equipped)

GSXS1000 Service Data

Useful links

GSXS1000 Service Schedule

Torque Settings

 

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