Supersport GSX-R1000K5 1.00 ENGINE KEY FEATURES OF THE GSX-R1000K5 ENGINE Increased displacement (999cc) Siorter lighter pistons, higher RPM Enisrged cylinder ventilation holes Increased compression ratio Increased camshaft lift, duration and overlap Revised intake and exhaust porting Titanium valves New twin injector throttle bodies New style clutch back torque limiter Exhaust muffler internal size increased GSX-R1000K5 edeeececee .01 Crankcase Ventilation holes between cylinders to reduce pumping losses Pressure from downward movement of piston is moved to adjacent cylinder to aid upward piston movement Ventilation hole diameter increased VENTILATION HOLE DIAMETER K5 Diameter: 39 mm K4 Diameter: 35 mm 1.02 Oil Sump © Oil Sump depth increased 10mm * Improved oil supply under maximum accceration and cornering KS $suzuK! 2005 NEW MODEL TECHNICAL UPDATE SEMINAR Sc € € ¢€ ce e¢€ ecOmtggdaicgdgaed ae a ea a es a a a a ee GSX-R1000K5 1.00 ENGINE 1.03 Cylinder Head Decreased intake entry angle for improved charging efficiency Straighter intake with increased port width Increased exhaust port diameter Overall head dimensions same as K4 Cylinder bolts shortened, thinned and relieved to reduce weight 1.04 Cylinder Head Bolts * Head bolts strengthened * All dimensions reduced to save weight As MM A B C D_ €E K5: 10.0 25 9.1 7.5 93 K4: 11.5 30 9.5 8.0 105 Cylinder head bolt torque A new 4-step cylinder bolt tightening procedure was adopted to ensure equal and stable head torque. Oil the threads and washer of the head bolt prior to starting. 1. Torque the bolts in sequence to 3. 1Kgf/M (22.4Ib/ft). 2. Loosen the bolts completely in reverse sequence. 3. Re-torque the cylinder head bolts in sequence to the above specification. 4. Tighten the bolts an additional 60° NOTE: This is the same procedure prescribed for the GSX-R600K4 suzuKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 5Supersport GSX-R1000K5 1.00 ENGINE 1.05 Crankshaft Balancer * Counter balancer weight has been reduced according to the weight reduction of the pistons 1.06 Connecting Rod * Connecting rod small end diameter is increased 1mm + |- beam section has been strengthened + Shot peening process added to upper rod bearing journal surface for greater overall strength Service Notes: Use extra caution when cleaning the new shot-peened surface. Wipers and paper towels will leave material on the rod due to the rough surface. When servicing crankshafts and connecting rods clean all parts thoroughly, check clearances with Plastigauge, lube con- rod bolts with oil, torque in two increasing steps and replace rod bolts if there are signs of stretching or other damage. 1.07 Piston PISTON HEIGHT Increased bore: 73.4mm Forged aluminum alloy KS: 22.50mm Overall height reduced: 1.3mm K4: 22.30mm Crown increased: 0.20mm Skirt shortened: 1.50mm. Weight savings: 8g (0.2802) each Surface treatment: Tinning COMPRESSION RATIO KB: 12.5:1 Ka: 19.0mm 08 Piston Rings New L-shaped top ring Piston ring hard chrome plating replaced with PVD Chromium Nitride PVD CrNi is harder, thinner and more scuff and wear resistant with less friction Chamfered scraper ring Reduced ring friction and improved sealing Piston Rings Upper he 1.2mm $suzuKi 2005 NEW MODEL TECHNICAL UPDATE SEMINAR e € € € ic ¢€ ¢€ag a a a a a a a a a a a a aa ie GSX-R1000K5 1.00 ENGINE 1.09 Camshafts * Identification marks have been changed due to P/N change * Camshaft speci n changed at er L* 3 A ee ¥ CAMSHAFT IDENTIFICATION MARKING K5:intake - 18G IN "L", Exhaust - 18G EX "M" IN OPEN IN CLOSE EX OPEN EX CLOSE IN LIFT EX LIFT OVERLAP ; 42 BTDC 73 ABDC 57BBDC 38ATDC 9.6mm 8.3mm 80 : 37BTDC 72 ABDC 53BBDC 34ATDC 9.0mm 8.0mm 71 TAPPET CLEARANCE IN: 0.10 - 0.20MM EX: 0.20 - 0.30MM Service Notes: When performing routine maintenance or any time the camshafts are removed, follow the service manual closely upon reinstallation. All GSX-R camshafts are hollow for lightness and may break if the cam holders are not installed, tightened and torqued properly. 1.10 Valves * Increased intake valve head diameter for increased flow and power output Titanium one-piece valves replace steel/stellite composite valves 90.4 gram weight savings allows higher output RPM and red-line Valve stem diameter increased 4.0mm to 4.5mm Oxidation process (similar to anodizing) provides thin, hard, abrasion resistant TiO, surface penetrating treatment. Oxidation treatment improves anti-gall qualities and surface porosity absorbs lubricants, it adds strength, and improves fatigue resis- tance. VALVE FACE DIAMETER VALVE STEM DIAMETER IN EX IN/EX, K5: 30 24 45 Ka: 29 24 4.0 Peeerrrity Service Notes: Although Titanium is a suitable replacement for steel, some precautions apply. Titanium is stronger than steel but not as impact resistant. The TiO, oxidation coating provides many benefits to the surface of the valve however the valve itself can still be deformed if struck. Do not strike the valve tip after installing the cotters to ensure their seating. This can deform the tip of the valve causing uneven pressure on the shim and tappet. Additionally, Molybdenum di-sulfide paste is required on the valve stem upon reassembly to prevent galling on start-up. Valve seats can be resurfaced using Neway cutters however, lapping valves is prohibited. suzuKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR ZSupersport GSX-R1000K5 1.00 ENGINE 1.11 Tappets, Valve Springs, Spring Seats and Spring Retainer + Intake and exhaust tappet diameter same as K4 Dual valve springs with increased pressure on intake Increased intake and decreased exhaust spring free length Increased intake spring pre-load Valve Train Specifications KS Ka Tappet dimensions GUIDE DIAMETER: 4.5MM 4.0MM Spring Free length IN: 39 mm 38.5mm Spring Free length EX: 39mm 38.5mm Installed spring pre-ioad IN: 147N 137N (33.051b) (30.81b) Installed spring pre-load EX: 137N 137N (33.051b) (30.8Ib) 1.12 EFI System - Throttle Body Assembly & Fuel Injectors Twin, dual throttle body type with 75-80-75mm spacing Increased throttle bore |.D. Fast idle activated by SDTV Fuel injector changed from single to dual injectors; four-hole plate-type injector for improved fuel atomization Synchronization procedure same as K4 with an air screw on each throttle body and a single throttle plate balancing screw between #2 and #3 throttle bores New fuel rail "block" feeds both injector sets K5 Throttle Body 80mm ___ 75mm 4-hole injector (Primary & Secondary injectors are same) suZUKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR© © ee eC ian GSX-R1000K5 1.00 ENGINE 1.12 EFI System - Dual Fuel Injectors Secondary * Two fuel injectors used to fuel Mleciog supply fuel under heavy load oaneal conditions with greater throttle response Injectors aimed at throttle plates to increase atomiz- ation Fuel injectors are same part number Both fuel injectors controlled by the ECM Primary ini Throtile ; Secondary injector open Vole 42->44mm_ Primary Fuel as per the chart below Injector Secondary Injector Duration g 5 § 3 = = 8 8 g & § z ph Coty EC iily SECONDARY INJECTOR OPERATION Chart shows secondary injector volume as a percentage of the total fuel injected volume Secondary injector operates at more than 4500 RPM OR Secondary injector operates at more than 30% rate of opening the TPS (rapid throttle opening) In the example above; at 8000 RPM an 80% ATPS the secondary injectors are supplying 75% of the total volume of fuel injected (Circled area) suzuki 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 9AY Cel ag 10 GSX-R1000K5 1.00 ENGINE 1.12 EFI System - Throttle Body Assembly - continued Throttle body assembly Idle speed Air screws screw Neuen el ee ee ay ; eae} est idle screw Ud eae Secondary injectors Throttle body synchronization Complete all services reccommended in the maintenance schedule such as valve adjustment prior to T.B. adjustment. Lift and support the fuel tank. Remove the air cleaner assembly from the throttle bodies. Remove the Intake Air Pressure Sensor (IAP) and the Intake Air Temperature Sensor(IAT) from the air cleaner. Leave the IAP sensor disconnected from the mani- folds and wiring harness (fail-safe mode). Re-connect the IAT. Adjust all 4 air screws; gently bottomed to 0 turns. With the engine at operating temperature, set the idle speed to 1150 RPM Use the #1 cylinder vacuum nipple to standardize the balancer @ 1150 RPM Connect the balancer gauge hoses to the vacuum ) nipples on each throttle body. The #4 throttle bore is the "master" (with the throttle cable attached) and its adjust- ment is dependent on the idle speed and air screw setting. 10. Adjust the balance between the #3 and #4 throttle bores with the #3 and #4 air screws. Open the corresponding screw for the highest (most vacuum) balancer ball first. (raising the idle speed raises the #4 ball, opening the air screw lowers the #4 ball) synchronization should be done at 1150 RPM. 11. Adjust the #1 or #2 air screws, whichever shows the highest vacuum to match the (18 2) gauge indication. 12.When 1 & 2 and 3 & 4 agree, proceed with balancing the two throttle body sets using the balance screw 13. Once balanced, check and readjust the engine idle speed to 1150 RPM. IDLE RPM 1150+ 100 RPM suzuki 2005 NEW MODEL TECHNICAL UPDATE SEMINAR € e € € € € ecaeana nee ge we a er a eo Se e GSX-R1000K5 1.00 ENGINE 1.12 EFI System - Throttle Body Assembly - continued TPS adjustment . Due to the close position of the TPS and STPS the special tool wiring harness is used to check and adjust the TPS. . Connect the harness and then a digital volt meter to the PINK/BLACK and BLACK/BROWN wires of the TPS harness. . If necessary adjust the TPS output voltage to 1.125 DC volts by changing the position of the TPS at idle (same as using the meter LCD-but more accurate). . Be certain the TPS is correctly adjusted at 1150 RPM Fast idle adjustment . Fast idle rarely requires adjustment. However it is easily checked after synchro- nization and TPS adjustment. With the unit assembled, adjust the fast idle speed to the specification below, using the fast idle screw AMBIENT FAST IDLE SPEED — IDLE SPEED. FAST IDLE DURATION TEMP + 5°C(23°F) 1500-2000 RPM 1150+ 100 Approx. 35 seconds 15°C(59°F) 1500-2000 RPM 1150+ 100 Approx. 17 seconds 25°C(77°F) 1500-2000 RPM 1150+ 100 Approx. 11 seconds 09930-82720: Mode selector switch 09913-13121: Balancer gauge set 09930-11950: Torx wrench 09900-28630: TPS inspection harness 99923-00585- LPT: Digital meter CAUTION: Use care to not drop any objects into the open throttle bodies once the air cleaner housing is removed. Remove the spacer from the front fuel tank mount cushion as this spacer could easily fall into the throttle body during service. NOTES: suzuKi 2005 NEW MODEL TECHNICAL UPDATE SEMINAR Ldodsaadng "Supersport 12 GSX-R1000K5 1.00 ENGINE 1.13 Air Cleaner Housing * Suzuki Ram Air Direct inlet has been modified to fit the new cowling shape * Intake efficiency improved by straightening the SRAD inlet and increasing inlet diameter Air cleaner housing same as K4 with increased throttle body inlet diameter 1.14 Exhaust System * Muffler capacity increased to reduce back pressure and maintain EPA sound levels * Triangulated shape moves mass towards vehicle's center of gravity and provides increased ground clearance Exhaust system constructed completely of titanium SET actuator now mounted inside the RH sub-frame rail New cables and adjustment lengths SET valve now part of the muffler, no "center - pipe" Exhaust muffler SET Troubleshooting K1 & K2 model GSX-R1000s may occasionally give an intermittent C-46 (SET) code 3 and later models SET pulleys were changed to reduce cable stretching and subsequent codes When a customer complains of an FI light coming on while riding but "resets" itself after the unit has cooled or the ignition switch has been turned off , you must test ride to full operating temperature to duplicate the complaint (cont.) suzuKi 2005 NEW MODEL TECHNICAL UPDATE SEMINARGSX-R1000K5 1.00 ENGINE 1.14 Exhaust System (cont.) - Suzuki Exhaust Tuning 40-41mm 1.D: 41GOCL 16-17mm tack \ SET Troubleshooting (continued) * If no adjustments or repairs have been completed: * Usually the "pull" cable needs to be tightened; follow the service manual procedure to put the actuator in the "adjust" position. Caution: Adjusting cable tension not in the “adjust” position WILL damage the actuator gears * Once in the "adjust" position ® , adjust the pull cable until the cables are taut at the actuator pulley [point T}{this will usually be tighter than seems comfortable) * Test ride the unit to full operating temperature, do not return the unit to the customer until the Fl code no longer appears + /f previous repairs have been attempted: * Verity there is an Fl code as above * With the engine off, turn on the ignition and inspect the SET valve sta pb Cet tyEClily ip sequence (open-closed-start positions) to check for proper operation and conditionof the actuator gears © If repairs or parts replacement is needed, remove the actuator and mid pipe from J the unit, it is easier to set-up the system on the work bench * When replacing components, the cables will need to be reset, follow the service * Prior to reinstallation connect the actuator harnesses (motor drive & EXCV position suZUKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 13 manual to adjust the cables and valve pulley clearance for the correct model year sensor) and cyle it through the start-up sequence several times * Engine off, mode switch on, set the actuator to the "adjust" position tighten the pull cable until taut and check for Fl code Reassemble and test ride to full temperature to ensure proper repairATT sel ag 14 GSX-R1000K5 1.00 FUEL PUMP, COOLING & 2.00 DRIVE 1.15 Fuel Pump + New fuel pump uses variable resistor to control fuel warning light * Variable resistor is used instead of 3 thermistors (K4 = 2) + New reserve mileage function in odometer requires three fuel leve! measurements + See meter section on reserve mileage function Fuel Pump Pump motor Fuel strainer Variable I resistor —~ a Gauge float. 1.16 Radiator * Radiator fluid capacity, dimensions and cooling capacity are increased ‘+ Trapezoidal shape * Radiator mounted fan thermo switch replaced by under-seat relay * ECM controls the fan based on coolant temperature sensor on engine RADIATOR CHANGES KB ka Width-upper 400mm = 340mm Width lower 253mm. Height 274mm —- 248mm Depth 22mm 22mm Collant capacity 2.515L 2.150L Cooling Capacity 31.5Kw —_26.8Kw 2.01 Primary Drive (clutch) Service Notes: With the use of the improved * Overall dimensions remain unchanged clutch back torque limiter it is critical 10 * Improved clutch plate material ensure proper clutch adjustment at 1/2 turns * Increased back torque limiter function 280K from lightly bottomed. Take the oppor- tunity to check this important adjustment whenever your customer's GSX-R1000's @® are in for service. $suZUKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR=] = = = = = = = = = = = = = = = = = = = = = = ara af ar at at ar 2.01 Clutch (cont.) CLUTCH PLATE @ = DRVPLT1 ® DRVPLT2 @ DRVPLT3 © —-DRN PLT 2.03 Back Torque Limiter * New style back torque limiter * Similar design as recent GP machines * Back torque cam preloaded by .diaphragm springs Limiter transfer pin protrusion: 0.2 - 0.4mm Limiter Cam Operation — No load | driven cam Back torque from transmission Accelerating GSX-R1000K5 2.00 DRIVE COLOR I.D. purple none black Back Torque Limiter Limiter Diaphragm drive cam pence pb loli EC iy suzuKi 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 15Supersport 16 GSX-R1000K5 2.00 DRIVE 2.01 Clutch (cont.) Operation Upon deceleration the engine braking force rotates the limiter cams relative to each other. The drive cam rides up the ramps of the driven cam forcing the driven cam toward the back of the clutch inner hub. Three pins in the pressure plate protrude from the rear of the earch inner hub. When the driven cam moves toward the inner hub, contact is made with the pressure plate pins. The pressure plate is then released from contact with the clutch allowing slight slippage and lessening engine braking transmitted to the rear whee! Back Torque Limiter Diaphragm springs Drive cam Pressure plate CAUTION: The new style back torque limiter is very effective at reducing the effect of rear wheel engine braking. Proper operation is dependent on clutch plate condition. If the oluteh actuating mechanism (worm gear) is too tight; once clutch wear begins, the limiter system may accelerate wear. MPORTANT: Check and adjust the worm gear at set-up and all service intervals. WARNING: The back torque limiter is pre-set from the factory. Improper adjustment of the limiter System could lead to possible freewheeling during deceleration or excessive engine braking of the rear wheel. Each situation could lessen rider control possibly leading to an accident Adjust the limiter pins as per the service manual. suzuki 2005 NEW MODEL TECHNICAL UPDATE SEMINARGSX-R1000K5 2.00 DRIVE 3.00 ELECTRICAL « 2.02 Transmission © Shift fork pin shape changed to improve shifting feel and smoothness + Drive chain strength increased 16% by increasing inner plate thickness by 0.2mm © Service Notes: Transmission shifting components are not interchangeable between the GSX-R1000K5 and previous GSX-R1000K4 models. Never interchange parts between models or model- years unless the interchange is called out on K4 the Genuine Suzuki Parts microfiche or in 7 KS © the Parts Price Guide. 3.00 ELECTRICAL 3.01 Combination Meter * New meter assembly includes: Gear position indicator Odometer, Twin tripmeters Adjustable RPM indicator 5,000-13,750 range RPM light now has 5 lamp brightness levels Three lamp modes; OFF, ON, Blinking Factory setting; 11,000 RPM, OFF mode, Brightness level 3 “Reserve trip” function calculates remaining mileage once fuel warning lamp is on Gear position indicator 000, Trip, Reserve trip LCD Peters SELECT RPM indicator lamp ae a a a a a a a a a aa a suzuKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 7GSX-R1000K5 3.00 ELECTRICAL 3.01 Combination Meter (cont.) Setting RPM Indicator lamp IG switch: “Turn off T — | SEL button: “Push & Hold” |! 1G switch: “Tum on ; L SEL button: “Push” Level 1 (Min) 0 20 30 40 5(Max) | | Sighness eel ‘ | ADJ button: “Push’ | E 4 "| _ Indicator starts lighting in the selected mode and brightness, st Sf KSEE oa fon: “Push” | tachometer needle points tothe present setting RPM, ., 50000 5500 > 192500 136000 13750 | | ADJ button: “Push’ | Completes Setting and Retums to Normal Display ~~" Setting is not cancelled by turning ignition off. Fuel warning and Reserve trip meter * Fuel Warning Indicator (no fuel gauge) + Two Modes: Off > Blinking (Approx. 4L) > ON (Approx. 2L) Reserve Trip Meter * Display:0.0 - 999.9 Miles Reserve trip meter turns on when fuel warning lamp illuminates Calculates mileage to empty Auto reset More than 1/2 tank full AND Speed is more than § MPH AND Operation is more than 40 seconds * Manual reset: With more than 1/2 tank, use SEL button to select Res Trip, while holding SEL, push ADJ for 5 seconds Aa sel tg Service Notes: The RPM indicator lamp can be set to alert the rider when the maximum recommended engine RPM is reached during the initial break-in period. Ask your GSX-R1000K5 customers if they are interested in having the RPM indicator set to match the Owner's Manual engine speed recommendations. Provide education to your customers on how to use and adjust the RPM indicator. Caution them that this function does not replace the need for appropriate engine and transmission operation i $suzuKI 2005 NEW MODEL TECHNICAL UPDATE SEMINARar oar a oa a? Br GF a? = = = = = = = = = = = = = = GSX-R1000K5 3.00 ELECTRICAL 3.02 Lamps * Head-lamp assembly uses a stacked-type * Only one bulb is illuminated on high or low-beam * Similar to Hayabusa * Pilot lamps are used in the low beam reflector Upper bulb (low beam): H7 (55w) Lower bulb (hi beam): — HB3 (60w) Pilot lamp (2): 12V/5w : @ ‘ 3.03 Tail-lamp and Signals Rear lamp changed to a 9 LED-type LED lamp has excellent vibration resistance (no bulb filaments to fail) and low electric consumption Tail lamp and signals have clear lenses Signals use amber bulbs SUZUKI 3.04 Wiring Harness * Fan relay replaces radiator mounted thermo-switch * Mode selector switch coupler conveniently located Radiator cooling fan relay pe Totty ET aty Mode switch suzuki 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 19AY Woe tg 20 GSX-R1000K5 4.00 CHASSIS KEY FEATURES OF THE GSX-R1000K5 CHASSIS Revised composite swingarm Reduced overall dimensions Improved radial-mount front brakes Sleek new bodywork & SRAD inlets Increased aerodynamics Integrated front turnsignsals mirrors) sa4eee 4.01 Frame GSX-R1000K5 Overall length: 2030 mm (79.9 in) Overall width: 710 mm (27.9 in) Overall h 1130 mm (44.5 in) Wheelbase 1405 mm (55.3 in) Ground clearance: 135 mm (5.3 in) Seat height: 810 mm (31.9 in) Dry weight: 166 kg (366 Ib) Trail: 96mm (3.78in) Rake: 23°45" GSX-R1000K4 2070mm (81.5in) 71.5mm(28.1in) 1145mm (45.1in) 1410 (55.5) 130mm (5.1in) 830 (32.7) 168 kg (372 Ib) 91mm (3.58) 27° Frame dimension - 18mm suZUKI 2005 NEW MODEL TECHNICAL UPDATE SEMINAR— & & © eeuwtoradg ee ee es a es a at es oe ee ae a ae a a a a a a a oa © © GSX-R1000K5 4.00 CHASSIS 4.02 Body © Cowling redesigned * Frontal area reduced 4% * Aerodynamic drag reduced 5% + Front turn signals integrated to mirrors 4.03 Front Brakes * Radial mount four-piston/two-pad front brake calipers * Front brake rotor diameter is increased 10mm (thickness 5.5mm) * Dowels anchor the calipers to fork lowers for increased rigidity * Brake pad shims added to increase pad life, reduce brake sounds, reduce chatter Caliper support wu 3 i g 4 Counterbores in caliper for dowels Front brake pad shim (OD Direction of disc rotation ——_—_, suzuki 2005 NEW MODEL TECHNICAL UPDATE SEMINAR 21AT tol te 22 GSX-R1000K5 4.00 CHASSIS 4.03 Swingarm * Multi component swingarm construction ‘+ Stampings and castings used * Separate swingarm bearing dust seals eliminated * Integrated oil seals on swingarm bearings Cast aluminum alloy ‘Stamped aluminum Cast aluminum alloy GSX-R600K5 No Technical Changes GSX-R750K5 No Technical Changes NOTES: suzuKi 2005 NEW MODEL TECHNICAL UPDATE SEMINAR