MOTORCYCLE DIVISION 4-STROKE

BULLETIN GS/GSX/GSX-R NO. 165

DATE: 5/16/2007

SUBJECT: SERVICE MANUAL CORRECTION -

GENERATOR ROTOR TORQUE SPECIFICATION

MODEL: GSX-R1000K7

REFERENCE: GSX-R1000 SERVICE MANUAL (P/N 99500-39310-03E)

Pages 3-86 and 10-45

NOTICE:
This bulletin contains service manual correction information for the GSX-R1000K7. Insert a
copy of each of the attached pages of this bulletin into the service manual at the appropriate
page.

AFFECTED DEPARTMENTS:
The following departments in your dealership should be notified of this information:

⌧ Management ⌧ Service Warranty Sales ⌧ Parts Accessories

American Suzuki Motor Corporation

Technical Service Department
Motorcycle / ATV / Scooter
3-86 ENGINE

• Install the generator rotor onto the crankshaft.

• Hold the generator rotor with the special tool and tighten its
bolt to the specified torque.
# 09930-44520: Rotor holder
$ Generator rotor bolt: 130 N·m (13.3 kgf-m, 96.0 lb-ft)

GENERATOR COVER
• Apply bond lightly to the mating surfaces at the parting line
between the upper and middle crankcases as shown.
* 99000-31140: SUZUKI BOND “1207B” or equivalent

• Install the dowel pins and new gasket 1.

"
Use a new gasket to prevent oil leakage.

• Install the generator cover and tighten the generator cover

bolts to the specified torque.
$ Generator cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
(
Be careful not to pinch fingers between the generator
cover and crankcase.

"
Use new gasket washers to prevent oil leakage.

NOTE:
* Fit the gasket washers to the bolts A.
* Fit the clamp to the bolt B.
 SERVICING INFORMATION 10-45

TIGHTENING TORQUE
ENGINE
ITEM N·m kgf-m lb-ft
Exhaust pipe bolt 23 2.3 16.5
Muffler connecting bolt 23 2.3 16.5
Muffler mounting bolt 25 2.5 18.0
Muffler chamber bracket bolt 25 2.5 18.0
Muffler chamber mounting bolt 23 2.3 16.5
Muffler joint nut 25 2.5 18.0
Speed sensor rotor bolt 25 2.5 18.0
Speed sensor bolt 6.5 0.65 4.7
Engine sprocket nut 115 11.5 83.0
Engine mounting bolt and nut (M: 10) Bolt 55 5.5 40.0
(M: 10) Nut 75 7.5 54.0
Engine mounting thrust adjuster 23 2.3 16.5
Engine mounting thrust adjuster lock-nut 45 4.5 32.5
Engine mounting pinch bolt 23 2.3 16.5
Cylinder head cover bolt 14 1.4 10.0
Spark plug 11 1.1 8.0
Cam chain guide No. 1 bolt 23 2.3 16.5
Camshaft journal holder bolt 10 1.0 7.0
Cam chain tension adjuster cap bolt 23 2.3 16.5
Cam chain tension adjuster mounting bolt 10 1.0 7.0
Cam chain tensioner bolt 23 2.3 16.5
Cylinder head bolt Step 1/step 3 31 3.1 22.5
(M: 10)
Final step 60°
(M: 6) 10 1.0 7.0
PAIR reed valve cover bolt 10 1.0 7.0
Water jacket plug 9.5 0.95 6.9
Water inlet cover bolt 10 1.0 7.0
Clutch cover bolt 10 1.0 7.0
Clutch sleeve hub nut 95 9.5 68.5
Clutch spring set bolt 10 1.0 7.0
Clutch lifter adjuster lock-nut 23 2.3 16.5
Starter clutch cover bolt 10 1.0 7.0
Starter idle gear cover bolt 10 1.0 7.0
Valve timing inspection plug 11 1.1 8.0
Starter clutch bolt 55 5.5 40.0
Generator cover bolt 10 1.0 7.0
Generator rotor bolt 130 13.3 96.0
Generator stator set bolt 11 1.1 8.0
Gearshift cam stopper bolt 10 1.0 7.0
Gearshift cam stopper plate bolt 13 1.3 9.5
Gearshift fork shaft retainer bolt 10 1.0 7.0
Gear position switch bolt 6.5 0.65 4.7
Oil pressure switch 14 1.4 10.0
Oil filter 20 2.0 14.5