MOTORCYCLE DIVISION 4-STROKE BULLETIN NO. GS/GSX/GSX-R - 97 REVISED DATE: 9/2/98 MODEL: SUBJECT: REFERENCE: GSX-R750W FUEL HOSE DISCONNECTED FROM FUEL PUMP NEW FUEL PIPE SET (PN 15310-33E50) SERVICE MANUAL (PN 99500-37080-03E) & SERVICE MANUAL SUPPLEMENT (99501-37200-03E) This bulletin contains revised parts and repair information. Follow the recommendations and instructions in this bulletin when installing the new fuel pipe set, fuel pump gasket and mounting bolts. Discard the original GSX-R #97 bulletin dated 8/14/98 and place this version in your service bulletin set. NOTICE: In certain regions of the country, the hose connecting the fuel pump to the fuel filter may come off causing a lack of fuel pressure to the fuel injection system. The fuel pump will operate normally when the ignition is turned on, but the engine will not start because fuel is not pumped into the fuel injection system. If you encounter this symptom, inspect the fuel pump output. If faulty, remove the fuel pump assembly from the fuel tank and see if the fuel hose has come off the fuel pump or fuel filter. If so, replace the hose and original clamps with a Fuel Pipe Set (PN 15310-33E50). The fuel pipe set has a pair of hoses, new hose clamps, and a pipe/ bracket combination which will secure the fuel pipe and hoses to the fuel pump bracket with screws. Use a new Fuel Pump Gasket (PN 44596-02F01) and new Fuel Pump Mounting Bolts (PN 15211-02F00, Qty. 8) when reinstalling a repaired fuel pump into the fuel tank. The new fuel pump mounting bolts have a different torque specification than the original bolts (see page 4 of this bulletin). AFFECTED MODELS: Some 1998 GSX-R750W models may be affected. No action is required unless the motorcycle will not start due to a lack of fuel pump output. - 1 -
hose ORIGINAL FUEL HOSE PN 15812-33E50 is secured to pump bracket with screws NEW FUEL PIPE SET PN 15310-33E50 and bracket assembly PARTS INFORMATION: Order the parts listed below from the Suzuki Parts Department as needed. Part Description Part Number Qty. Fuel Pipe Set 15310-33E50 1 Fuel Pump Gasket 44596-02F01 1 Mounting Bolts 15211-02F00 8 CORRECTIVE ACTION: Carefully read and follow the instructions, warnings and cautions in section 4 of the GSX-R750 Service Manual Supplement (PN 99501-37200-03E) before beginning service. Verify fuel pump operation by performing the fuel pressure inspection outlined on page 4-50 and the fuel discharge amount inspection on page 4-51. 09940-40210 Fuel pressure gauge adaptor 09915-77330 Oil pressure gauge 09915-74520 Oil pressure gauge hose FUEL PRESSURE: FUEL DISCHARGE AMOUNT: 41 psi (2.9kg/cm 2, 250kPa) 1.1 oz/3 seconds (26-30ml/3 seconds) Gasoline is highly flammable, explosive and toxic. Keep heat, sparks and flame away. If the fuel pump does not meet the fuel pressure and discharge specifications, the fuel pump assembly will need to be removed and inspected. - 2 -
INSTALLING THE FUEL PIPE SET: Remove the fuel tank (see page 4-49) Remove the fuel pump assembly from the fuel tank by removing the mounting bolts (see page 4-51). 1 hose ORIGINAL Fuel Pump (Fig 1) If the fuel pump hose has come off the fuel pump or filter, remove it completely from the fuel pump assembly and replace it with the fuel pipe set. Fuel pump CAUTION Do not reuse a fuel pump hose that has come off the pump or filter fitting. Replace the hose with a new fuel pipe set. Do not reuse the original hose clamps. Only use the new clamps from the fuel pipe set. & bracket (Fig 2) Slip the hoses onto the fuel pump and fuel filter fittings. Secure the pipe/bracket to the fuel pump assembly bracket with the new screws provided with the pipe set. CAUTION The fuel pump fitting, fuel filter fitting and new fuel pipe and hoses must be free of gasoline or other residue or the hoses may not stay secured on the pump assembly. NEW Fuel Pipe Set 2 Fuel Pipe Set Mounting & bracket Screw - 3 - The new pipe and hoses need to be thoroughly cleaned with contact cleaner, or a similar solvent, to remove any "release agent". The "release agent", is a film left on the hose from the molding process.
(Fig 3) The new fuel pump mounting bolts are a flange-head style. The original bolts have a hex head with a lock washer. 3 Fuel Pump Mounting Bolts The fuel pump gasket and mounting bolts must be replaced with a new a fuel pump gasket and new style mounting bolts to prevent fuel leakage. Clean the fuel pump mounting flange on the fuel tank. Install the new fuel pump gasket on the fuel tank before reinstalling the fuel pump. ORIGINAL Hex Head NEW Flange Head NOTE: Make sure the mounting bolt holes in the fuel tank and gasket align before attempting to install the fuel pump. 4 Mounting Bolt Tightening Sequence Gently slide the fuel pump into the fuel tank. Take care to not disturb the fuel pump gasket. Turn the new fuel pump mounting bolts lightly in by hand until they are seated. 6 1 4 (Fig. 4 & 5) Perform the mounting bolt tightening sequence in three steps: Torque the mounting bolts to the initial torque (1.8 lb-ft) following the correct sequence. " Torque the bolts to final torque (2.9 lb-ft) following the correct sequence. #Torque the bolts once again to the final torque (2.9 lb-ft) in the correct sequence. 7 2 FRONT 5 3 8 Failure to follow the fuel pump mounting bolt torque specifications and tightening sequence could cause improper gasket sealing and fuel leakage. 5 Mounting Bolt Torque Steps & Specifications DO NOT OVER TIGHTEN THE MOUNTING BOLTS. Reinstall the fuel tank, following the instructions on pages 4-49 and 4-50 of the GSX- R750W service manual supplement (PN 99501-37200-03E). Clean and polish any fingerprints from the motorcycle. Add fuel so the fuel amount is at least the amount the customer had in the motorcycle before the fuel hose repair. (1) Initial torque...1.8lb-ft (21.6lb-in, 2.5N.m, 0.25kgf.m) (2 & 3) Final torque...2.9lb-ft (34.8lb-in, 4.0N.m, 0.4kgf.m) NOTE: A 1/4" drive torque wrench, calibrated in lb-in, works well on the low-torque mounting bolts. - 4 -
RIDE THE MOTORCYCLE: To ensure customer satisfaction, Suzuki suggests you ride the motorcycle several miles to make sure there are no fuel leaks and all the controls and the motorcycle operate correctly. ADVISE THE CUSTOMER OF THE FUEL LEVEL WHEN YOU DELIVER THE MOTORCYCLE. Correct any fuel pipe set repair related problems before delivering the motorcycle to the customer. AFFECTED DEPARTMENTS: The following departments in your dealership should be notified of this information: *Service * Parts *Sales Accessories American Suzuki Motor Corporation Technical Service Department Motorcycle - 5 -