Suzuki GSX 1400 2002 2005 User Manual

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG1

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 1 of 86

GASKET SET

 

Ref No

Part No

Description

 

 

 

1

11401-42811

Gasket Set

2

11141-42F00

• . Gasket, Cylinder Head

3

11173-42F01

• . Gasket, Head Cover

4

11182-35F00

• . Gasket, 2nd Air Passage

5

11241-42F00

• . Gasket, Cylinder

6

11482-42F00

• . Gasket, Clutch Cover

7

11483-42F00

• . Gasket, Magneto Cover (na)

8

11484-42F01

• . Gasket, Breather Cover (na)

9

11489-42F00

• . Gasket, Oil Pan (na)

10

11491-42F00

• . Gasket, Signal Generator Cover (na)

11

12837-35F00

• . Gasket, Tensioner Adjuster

12

14181-46E00

• . Gasket, Exhaust Pipe

13

16491-27A01

• . O Ring, Oil Pan

14

16527-42F00

• . Gasket, Oil Strainer Cover (na)

15

16529-27A01

• . Gasket, Oil Outlet

16

09161-11008

• . Washer

17

09280-12012

• . O Ring (d:2.4,id:11.8)

18

09280-15003

• . O Ring (d:2.4,id:14.8)

19

09280-42003

• . O Ring

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG2

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 2 of 86

CYLINDER HEAD COVER

 

Ref No

Part No

Description

 

 

 

1

11171-42F00

Cover Cylinder Head

2

11173-42F01

Gasket, Head Cover

3

09106-07009

Bolt, Head Cover

4

07120-08503

Bolt, Head Cover

5

09161-11008

Washer, Head Cover

6

07130-08123

Plug, Head Cover

7

09168-08029

Gasket

8

09206-08007

Knock Pin

9

11182-35F00

Gasket, 2nd Air Passage

10

11330-42F00

Cover, Breather

11

11484-42F01

Gasket, Breather Cover (na)

12

01547-06303

Bolt, Breather Cover

13

01547-06307

Bolt, Breather Cover Earth

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

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GSX1400K2 (GSX1400K2 E2)

FIG3

 

CYLINDER HEAD

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

11100-42F00

Head Assy, Cylinder

 

 

 

 

2

09381-10004

• . Snap Ring

 

 

 

 

3

09103-06026

• . Bolt, Camshaft Housing

 

 

 

 

4

09206-08001

• . Knock Pin

 

 

 

 

5

11115-18D72

Guide, Valve (os:0.3)

 

 

 

 

6

11141-42F00

Gasket, Cylinder Head

 

 

 

 

7

04211-11169

Pin

 

 

 

 

8

01550-06353

Bolt, Cylinder Head Bolt

 

 

 

 

9

09168-10031

Gasket, Cylinder Head Bolt

 

 

 

 

10

11138-42F00

Plate, Head Reinf

 

 

 

 

11

11131-27A00

Pipe, Oil

 

 

 

 

12

11134-42F00

Pipe, Cylinder Head

 

 

 

 

13

01550-06403

Bolt, Oil Pipe

 

 

 

 

14

08322-01063

Washer, Oil Pipe Bolt

 

 

 

 

15

07120-06703

Bolt, Cylinder Head

 

 

 

 

16

09482-00413

Spark Purge U24etr (ngk)

 

 

 

 

16

09482-00412

Spark Purge Cr8ek (ngk)

 

 

 

 

16

09482-00415

Spark Purge U22etr (nd)

 

 

 

 

16

09482-00414

Spark Purge Cr7ek (ngk)

 

 

 

 

16

09482-00411

Spark Purge U27etr (nd)

 

 

 

 

16

09482-00410

Spark Purge Cr9ek (ngk)

 

 

 

 

17

13101-42F00

Pipe Assy, Intake No.1

 

 

 

 

18

13102-42F00

Pipe Assy, Intake No.2

 

 

 

 

19

13103-42F00

Pipe Assy, Intake No.3

 

 

 

 

20

13104-42F00

Pipe Assy, Intake No.4

 

 

 

 

21

09280-42003

• . O Ring, Intake Pipe

 

 

 

 

22

09402-58208

Clamp, Intake Pipe

 

 

 

 

23

02122-06163

Screw, Intake Pipe

 

 

 

 

24

09106-08140

Plug, Cylinder Head

 

 

 

 

25

09168-08029

Gasket, Cylinder Head

 

 

 

 

26

13650-42F00

Sensor, Oil Temp

 

 

 

 

27

13652-42F00

• . O Ring

 

 

 

 

28

07120-06123

Bolt, Cylinder Head

 

 

 

 

29

09103-10328

Bolt, Cylinder Head L195

 

 

 

 

30

09108-10139

Bolt, Cylinder Stud

 

 

 

 

31

09159-10069

Nut, Cylinder Head

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG4

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 4 of 86

CYLINDER

 

Ref No

Part No

Description

 

 

 

1

11211-42FA0-0F0

Cylinder

2

11241-42F00

Gasket, Cylinder

3

09108-06002

Bolt, Stud

4

08316-10063

Nut, Cylinder

5

09206-13017

Knock Pin

6

11282-42F00

Hose, Cylinder Head Oil

7

09360-10032

Bolt, Union

8

09168-10007

Gasket (10.1x16x1)

9

11328-42F01

Hose, Oil Head Cooler

10

09280-14011

0 Ring (d:2.5 Id:13.8)

11

09280-15007

0 Ring (d:2.4 Id:15.8)

12

07130-06163

Bolt

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

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GSX1400K2 (GSX1400K2 E2)

FIG5

CRANKCASE

 

 

 

Ref No Part No

Description

 

 

 

 

111301-42810

211319-33E50

301550-08603

409103-09005

509103-09009

609106-06075

701547-06353

801547-06553

901550-06203

1001550-08603

1101550-08753

1209106-08116

1309168-08015

1409168-08016

1509168-10031

1609168-12002

1709168-16002

1809246-05006

1909247-12006

2009248-16012

2109280-04004

2209280-08012

2309103-06126

2409103-06255

2509493-24010

2611390-42F00

2711323-42F00

2812228-24F00-0D0

2912228-24F00-0A0

29

12228-24F00-0B0

29

12228-24F00-0C0

29

12228-24F00-0D0

29

12228-24F00-0E0

2912228-24F00-0F0

3011681-06B00

3109100-12044

3209103-10146

3309103-10335

3409103-10336

3509159-10020

3609159-10103

3709159-12054

3808322-01123

3908316-10103

4011281-42F00

4109280-14011

4237820-33D10

4337822-33D00

Crankcase Set

. Pin

. Bolt

. Bolt (l:135)

. Bolt (l:105)

. Bolt Piston Cooling Jet

. Bolt

. Bolt

. Bolt

. Bolt

. Bolt

. Plug, Oil Gallery

. Gasket, Oil Gallery

. Gasket

. Gasket

. Gasket, Oil Gallery Plug

. Gasket, Oil Gallery Plug

. Plug, Oil Gallery

. Plug, Oil Gallery

. Plug, Oil Gallery

. 0 Ring, Piston Cooling Jet

. 0 Ring

. Bolt

. Bolt

. Jet, Oil Gallery

. Jet, Piston Cooling

. Separator, Oil

. Bearing, Crank Thrust (green)

. Bearing, Crank Thrust (red)

. Bearing, Crank Thrust (black)

. Bearing, Crank Thrust (blue)

. Bearing, Crank Thrust (green)

. Bearing, Crank Thrust (yellow

. Bearing, Crank Thrust (white) Bush, Engine Mount Front

Bolt L:140 Bolt L:155 Bolt L:50 Bolt L:60

Nut, Center Lower Nut, Upper

Nut, Lower Washer, Lower Nut, Front

Pipe, Oil Main Gallery O Ring

Switch Assy, Oil Pressure

. Bolt

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 6 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG6

 

CRANKCASE COVER

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

11340-42F00

Cover, Clutch

 

 

 

 

2

11971-33210

• . Lens, Oil Level

 

 

 

 

3

11482-42F00

Gasket, Clutch Cover

 

 

 

 

4

04211-09189

Pin, Clutch Cover

 

 

 

 

5

09103-06213

Bolt (l:30)

 

 

 

 

6

11971-25D00

Plug, Oil Filler

 

 

 

 

7

09280-17003

O Ring

 

 

 

 

8

11342-42F00

Plate, Clutch Cover

 

 

 

 

9

01550-06123

Bolt

 

 

 

 

10

11343-42F00

Damper, Clutch Cover

 

 

 

 

11

11381-42F00

Cover, Signal Generator

 

 

 

 

12

11491-42F00

Gasket, Signal Generator Cover

 

 

 

 

13

09103-06212

Bolt (l:25)

 

 

 

 

14

09168-06023

Gasket

 

 

 

 

15

11351-42F01

Cover, Magneto

 

 

 

 

16

11483-42F00

Gasket, Magneto Cover

 

 

 

 

17

04211-09149

Pin, Magneto Cover

 

 

 

 

18

09103-06213

Bolt (l:30)

 

 

 

 

19

09168-06023

Gasket

 

 

 

 

20

11371-42F10

Cover, Engine Sprocket Inner

 

 

 

 

21

01547-06653

Bolt

 

 

 

 

22

04211-09149

Pin

 

 

 

 

23

11360-42F00

Cover, Engine Sprocket Outer

 

 

 

 

24

09180-06307

• . Spacer (6.5x9x10)

 

 

 

 

25

09180-06275

• . Spacer (6.5x9x23)

 

 

 

 

26

09103-06214

Bolt

 

 

 

 

27

11362-42F00

Damper, Engine Sprocket Cover Outer

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG7

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 7 of 86

OIL PAN

 

Ref No

Part No

Description

 

 

 

1

11511-42F00

Pan, Oil

2

11489-42F00

Gasket, Oil Pan

3

01550-06303

Bolt (l:30)

4

01550-06403

Bolt (l:40)

5

01550-06503

Bolt (l:50)

6

09168-06023

Gasket

7

09247-14036

Plug, Oil Drain

8

09168-14002

Gasket, Oil Drain

9

09248-16012

Plug, Oil Gall

10

09168-16002

Gasket

11

16520-42F00

Strainer Assy, Engine Oil

12

16521-42F00

• . Strainer

13

16525-42F00

• . Protector, Oil Strainer

14

16526-42F00

• . Cover, Oil Strainer

15

16527-42F00

• . Gasket

16

01550-06203

• . Bolt, Oil Strainer Cover

17

01550-06253

Bolt, Oil Strainer

18

01550-06603

Bolt, Oil Strainer

19

16529-27A01

Gasket, Oil Outlet

20

09280-40010

O Ring

21

16440-42F00

Valve Assy

22

16442-34301

Plunger, Oil Control

23

09168-16002

Gasket

24

09248-16012

Plug, Oil Control Plunger

25

09440-09023

Spring, Oil Control

26

09280-18009

O Ring, Oil Pump Out

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG8

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 8 of 86

OIL PUMP

 

Ref No

Part No

Description

 

 

 

1

16510-03G00-X07

Filter Assy, Engine Oil

2

16400-42F10

Pump Assy, Oil

3

16491-27A01

O Ring

4

09280-18009

O Ring, Oil Pump Out

5

09106-06089

Bolt

6

09106-06088

Bolt

7

04211-09149

Pin

8

16321-42F00

Gear, Oil Pump Drive

9

16331-26D01-0B0

Gear, Oil Pump Driven

10

08221-12205

Washer

11

09261-05006

Pin

12

08331-31126

Circlip

13

16481-42F00

Pipe, Oil Outlet

14

09280-22016

O Ring

15

16530-42F00

Pipe, Oil Outlet Under

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG9

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 9 of 86

CRANKSHAFT

 

Ref No

Part No

Description

 

 

 

1

12160-42F00

Connrod Assy

2

12163-24F00

• . Bolt

3

12165-27A50

• . Pin

4

12164-46E01-0A0

Bearing, Crank Pin (green)

4

12164-46E01-0B0

Bearing, Crank Pin (black)

4

12164-46E01-0C0

Bearing, Crank Pin (brown)

4

12164-46E01-0D0

Bearing, Crank Pin (yellow)

5

12000-42810

Crankshaft Set

6

04221-04089

• . Pin

7

12228-24F00-0D0

• . Bearing, Crank Thrust (green)

8

12228-24F00-0A0

• . Bearing, Crank Thrust (red)

8

12228-24F00-0B0

• . Bearing, Crank Thrust (black)

8

12228-24F00-0C0

• . Bearing, Crank Thrust (blue)

8

12228-24F00-0D0

• . Bearing, Crank Thrust (green)

8

12228-24F00-0E0

• . Bearing, Crank Thrust (yellow

8

12228-24F00-0F0

• . Bearing, Crank Thrust (white)

9

12229-24F00-0A0

Bearing, Crankshaft (green)

9

12229-24F00-0B0

Bearing, Crankshaft (black)

9

12229-24F00-0C0

Bearing, Crankshaft (brown)

9

12229-24F00-0D0

Bearing, Crankshaft (yellow)

11

12140-42F00

Ring Set, Piston

12

12151-07D00

Piston Pin

13

09381-18003

Circlip

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG10

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 10 of 86

STARTER CLUTCH

 

Ref No

Part No

Description

 

 

 

1

12611-42F00

Gear, Starter Idle

2

09206-11014

Pin, Starter Idle Gear

3

12600-42811

Clutch Set, Starter

4

09106-08095

Bolt, Starter Clutch, 8x16

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG11

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 11 of 86

CRANK BALANCER

 

Ref No

Part No

Description

 

 

 

1

12650-42F00-0F0

Shaft, Crank Balancer

2

12654-24F00-0F0

Balancer, Crank

3

12666-24F00

Gear, Crank Balance

4

12686-24F00

Damper, Crank Balancer

5

09263-19015

Bearing (19x26x25.2)

6

09180-19014

Spacer

7

09169-21001

Washer

8

09280-14015

O Ring

9

09280-17007

O Ring

10

12681-26D00

Arm, Balancer Shaft

11

07130-06203

Bolt

12

09103-06130

Bolt (6x20)

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG12

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 12 of 86

CAM SHAFT/VALVE

 

Ref No Part No

Description

 

 

112710-42F00

212741-42F00

309103-07001

412720-42F00

512741-42F00

609103-07001

712891-17E00

812911-42F00

912912-42F00

1012920-13E00

1112931-13E00

1212933-39E00

1312932-32C00

1409289-04002

1512892-05C00-120

15

12892-05C00-125

15

12892-05C00-130

15

12892-05C00-135

15

12892-05C00-140

15

12892-05C00-145

15

12892-05C00-150

15

12892-05C00-155

15

12892-05C00-160

15

12892-05C00-165

15

12892-05C00-170

15

12892-05C00-175

15

12892-05C00-180

15

12892-05C00-185

15

12892-05C00-190

15

12892-05C00-195

15

12892-05C00-200

15

12892-05C00-205

15

12892-05C00-210

15

12892-05C00-215

1512892-05C00-220

1612800-05830

1799000-69471

Camshaft, Intake

Sprocket, Cam Shaft

Bolt, Cam Sprocket, 7x11

Sprocket, Exhaust

Sprocket, Cam Shaft

Bolt, Cam Sprocket, 7x11

Tappet

Valve, Intake

Valve, Exhaust

Spring Set, Valve

Retainer, Valve Spring

Seat, Valve Spring

Cotter, Valve

Seal, Valve Stem Oil (4.5x10x8)

Shim, Tappet, T:1.20

Shim, Tappet, T:1.25

Shim, Tappet, T:1.30

Shim, Tappet, T:1.35

Shim, Tappet, T:1.40

Shim, Tappet, T:1.45

Shim, Tappet, T:1.50

Shim, Tappet, T:1.55

Shim, Tappet, T:1.60

Shim, Tappet, T:1.65

Shim, Tappet, T:1.70

Shim, Tappet, T:1.75

Shim, Tappet, T:1.80

Shim, Tappet, T:1.85

Shim, Tappet, T:1.90

Shim, Tappet, T:1.95

Shim, Tappet, T:2.00

Shim, Tappet, T:2.05

Shim, Tappet, T:2.10

Shim, Tappet, T:2.15

Shim, Tappet, T:2.20

Shim Set, Tappet

• . Case, Tappet Shim

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG13

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 13 of 86

CAM CHAIN

 

Ref No

Part No

Description

 

 

 

1

12760-42F00

Chain, Cam Shaft Drive

2

12771-42F00

Guide, Cam Chain No.1

3

12810-42F00

Tensioner, Cam Chain

4

12814-34200

Cushion

5

12782-42F00

Guide, Cam Chain No.2

6

09103-06026

Bolt (l:39)

7

01550-06123

Bolt (l:12)

8

12830-35F00

Adjuster Assy, Tensioner

9

12839-35F00

• . Ball

10

12831-35F00

• . Spring

11

12836-42F00

Bolt, Adjuster Spring

12

09168-12017

Gasket (12x17x1)

13

12837-35F00

Gasket, Tensioner Adjuster

14

07130-06253

Bolt, Tensioner Adjuster

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 14 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG14

 

THROTTLE BODY (MODEL K2)

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

13405-42F00

Throttle Body Assy

 

 

 

 

2

13271-44B00

• . Spring

 

 

 

 

3

13548-42F00

• . Screw

 

 

 

 

4

13268-96110

• . Spring

 

 

 

 

5

13605-39F00

• . Screw

 

 

 

 

6

13543-39F00

• . Spring

 

 

 

 

7

13673-39F20

• . Seal

 

 

 

 

8

13477-39F00

• . Harness Assy

 

 

 

 

9

13601-47A00

• . Screw

 

 

 

 

10

13267-44B00

• . Screw

 

 

 

 

11

13432-37100

• . Washer

 

 

 

 

12

13270-42F00

• . Adjust Screw Assy

 

 

 

 

13

13268-37420

• . Spring

 

 

 

 

14

95158-60D00

• . Bolt

 

 

 

 

15

13268-89J00

• . Spring

 

 

 

 

16

13580-42F00

• . Sensor Assy

 

 

 

 

17

13580-26F00

• . Sensor Assy

 

 

 

 

18

13612-34E00

• . Bolt

 

 

 

 

19

13586-13626

Nut

 

 

 

 

20

13614-39F00

Lock Washer

 

 

 

 

21

09404-06429

Clamp (l:60)

 

 

 

 

22

13607-39F00

Nut

 

 

 

 

23

13267-42F00

Screw

 

 

 

 

24

13268-42F00

Spring

 

 

 

 

25

13603-05108

Screw

 

 

 

 

26

13602-05108

Screw

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 15 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG14A

 

THROTTLE BODY (MODEL K3/K4/K5)

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

13405-42F00

Throttle Body Assy

 

 

 

 

2

13271-44B00

• . Spring

 

 

 

 

3

13548-42F00

• . Screw

 

 

 

 

4

13268-96111

• . Spring

 

 

 

 

5

13605-39F00

• . Screw

 

 

 

 

6

13543-39F00

• . Spring

 

 

 

 

7

13673-39F20

• . Seal

 

 

 

 

8

13477-39F00

• . Harness Assy

 

 

 

 

9

02112-34163

• . Screw

 

 

 

 

10

13267-44B00

• . Screw

 

 

 

 

11

13277-37100

• . Washer

 

 

 

 

12

13270-42F00

• . Adjust Screw Assy

 

 

 

 

13

13268-37420

• . Spring

 

 

 

 

14

95158-60D00

• . Bolt

 

 

 

 

15

13268-89J00

• . Spring

 

 

 

 

16

13580-42F00

• . Sensor Assy

 

 

 

 

17

13580-26F00

• . Sensor Assy

 

 

 

 

18

13612-34E00

• . Bolt

 

 

 

 

19

13586-13626

Nut

 

 

 

 

20

13614-39F00

Lock Washer

 

 

 

 

21

09404-06429

Clamp (l:60)

 

 

 

 

22

13607-39F00

Nut

 

 

 

 

23

13267-42F00

Screw

 

 

 

 

24

13268-42F00

Spring

 

 

 

 

25

02122-05103

Screw

 

 

 

 

26

02112-05107

Screw

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG15

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 16 of 86

THROTTLE BODY HOSE/JOINT (MODEL K2)

Ref No

Part No

Description

 

 

 

1

13672-33E00

Cushion, Fuel Injector

2

15710-65D00

Injector Assy, Fuel

3

15716-65DT0

• . Grommet Set, Fuel Injector

4

13602-42F00

Screw

5

15731-42F00

Pipe Assy

6

13431-42F00

Cover, Left

7

13602-42F10

Screw

8

13432-42F00

Cover, Right

9

13274-84000

Cap

10

13681-39F00-250

Hose

11

13681-39F00-250

Hose

12

13681-39F00-250

Hose

13

13681-39F00-250

Hose

14

13681-39F00-250

Hose

15

13471-02FA0

Nipple

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG15A

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 17 of 86

THROTTLE BODY HOSE/JOINT (MODEL K3/K4/K5)

Ref No

Part No

Description

 

 

 

1

13672-33E00

Cushion, Fuel Injector

2

15710-65D00

Injector Assy, Fuel

3

15716-65DT0

• . Grommet Set, Fuel Injector

4

13602-42F20

Screw

5

15731-42F10

Pipe Assy

6

13431-42F10

Cover, Left

7

13602-42F10

Screw

8

13606-42F10

Washer

9

13663-42F10

Holder

10

13485-42F10

Ring

11

13432-42F10

Cover, Right

12

13274-84000

Cap

13

13681-39F00-250

Hose

14

13681-39F00-250

Hose

15

13681-39F00-250

Hose

16

13681-39F00-250

Hose

17

13681-39F00-250

Hose

18

13685-02FA0

Nipple

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 18 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG16

 

AIR CLEANER

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

13700-42F01

Cleaner Assy, Air

 

 

 

 

2

13780-42F00

• . Filter Assy, Air Cleaner

 

 

 

 

3

02142-05123

• . Screw

 

 

 

 

4

13853-42F00

• . Tube, Breather

 

 

 

 

5

09401-14301

• . Clip

 

 

 

 

6

13881-42F00

• . Tube, Outlet

 

 

 

 

7

09402-50208

• . Clamp

 

 

 

 

8

13870-21368

• . Tube, Drain

 

 

 

 

9

09401-11101

•• .. Clip

 

 

 

 

10

09401-13417

• . Clip

 

 

 

 

11

01550-06123

Bolt

 

 

 

 

12

18591-42F00

Sensor, Boost

 

 

 

 

13

18595-42F10

Holder, Sensor

 

 

 

 

14

18591-42F00

Sensor, Air Pressure

 

 

 

 

15

18595-42F10

Holder, Sensor

 

 

 

 

16

13650-56B00

Sensor, Inlet Air Temp

 

 

 

 

17

09168-12017

Gasket (12x17x1)

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG17

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 19 of 86

MUFFLER (MODEL K2/K3/K4)

Ref No

Part No

Description

 

 

 

1

14150-42F00

Pipe, Exhaust Rh

2

14160-42F00

Pipe, Exhaust Lh

3

14170-42F00

Pipe, Exhaust Ctr Rh

4

14180-42F00

Pipe, Exhaust Ctr Lh

5

14182-42F00

Clamp, Exhaust Pipe

6

14210-42F00

Body, Manf

7

14771-32E00

Connector, Muf

8

09103-08365

Bolt, Muf Sprt Rr

9

14181-46E00

Gasket, Exhaust Pipe

10

09106-08104

Bolt (6x25)

11

09160-08145

Washer

14

01550-08403

Bolt

15

14780-42F00

Cover, Exhaust Pipe Rh

16

14790-42F00

Cover, Exhaust Pipe Lh

20

09160-06028

Washer (6.5x18x1)

21

09118-08068

Bolt (8x40)

22

09180-08152

Spacer (8.6x12x24.2)

23

09320-12048

Cushion

26

09160-08147

Washer

27

09180-08216

Spacer (8.6x12x25.2)

28

09320-12049

Cushion

29

09103-08358

Bolt, Muf Support

30

08361-25088

Nut

31

08322-01083

Washer

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 20 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG17A

 

MUFFLER (MODEL K5)

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

14150-42F30

Pipe, Exh, R

 

 

 

 

2

14160-42F30

Pipe, Exh, L

 

 

 

 

3

14170-42F30

Pipe, Exh Ctr, R

 

 

 

 

4

14180-42F30

Pipe, Exh Ctr, L

 

 

 

 

5

14181-46E00

Gasket, Exhaust Pipe

 

 

 

 

6

14182-42F00

Clamp, Exh Pipe

 

 

 

 

7

14210-42F30

Body, Manf

 

 

 

 

8

14310-42F40

Body, Muffler

 

 

 

 

8

14310-42F30

Body, Muffler

 

 

 

 

9

14459-42F30

Clamp, Muf Conn

 

 

 

 

10

14771-32E00

Connector, Exh Pipe

 

 

 

 

11

14771-42F30

Connector, Exh Pipe

 

 

 

 

12

09106-08165

Bolt, 8x25

 

 

 

 

13

09160-08145

Washer

 

 

 

 

14

09103-08365

Bolt, 8x35

 

 

 

 

15

09118-08068

Bolt, 8x40

 

 

 

 

16

09180-08152

Spacer, 8.6x12x24.2

 

 

 

 

17

09320-12048

Cushion

 

 

 

 

18

09103-08392

Bolt, 8x40

 

 

 

 

19

08322-01083

Washer

 

 

 

 

20

09103-08358

Bolt, 8x45

 

 

 

 

21

09160-08147

Washer

 

 

 

 

22

09180-08216

Spacer

 

 

 

 

23

09320-12049

Cushion

 

 

 

 

24

08361-25088

Nut

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG18

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 21 of 86

OIL COOLER

 

Ref No

Part No

Description

 

 

 

1

16600-42F10

Cooler Assy, Oil

2

16628-27A00

Cushion, Oil Cooler

3

09116-06171

Bolt, Oil Cooler (6x30)

4

09180-06296

Spacer, Oil Cooler

5

09320-10015

Cushion, Oil Cooler

6

16460-42F10

Hose, Oil Cooler, Lh

7

16470-42F10

Hose, Oil Cooler, Lh

8

16490-42F00

Clamp, Oil Hose

9

01550-06163

Bolt

10

09280-15003

O Ring, D:2.4 Id:14.8

11

09280-12012

O Ring, D:2.4 Id:11.8

12

07130-06203

Bolt, Oil Cooler Hose Lower

13

07130-06163

Bolt, Oil Cooler Hose Upper

14

16621-42F00

Cover, Oil Cooler

15

09139-06027

Bolt, Oil Cooler Cover

16

17680-39D00

Switch, Fan

17

09168-18009

Gasket, Fan Switch

18

17800-42F00

Fan Assy, Oil Cooler

20

17811-42F10

Guard, Oil Cooler Fan

21

09320-10015

Cushion, Oil Cooler Fan

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG19

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 22 of 86

FUEL PUMP

 

Ref No

Part No

Description

 

 

 

1

15100-42F01

Pump Assy, Fuel

2

15410-42F00

• . Filter Assy Fuel

3

15420-35F01

• . Strainer, Fuel Pump

4

15111-35F00

• . Cushion, Fuel Pump

5

15112-42F00

• . Holder, Fuel Pump

6

15114-35F00

• . Bush, Fuel Pump

7

15113-35F00

• . O Ring

8

15115-35F00

• . Nut

9

15116-35F10

• . Screw

10

15116-35F10

• . Screw, Fuel Gauge

11

15171-35F00

• . Washer

12

15172-35F00

• . Spring Washer

13

15173-35F00

• . Nut

14

15201-35F00

O Ring, Fuel Pump

15

15810-42F00

Hose, Fuel

16

07120-06123

Bolt

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 23 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG20

 

SECOND AIR

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

18450-42F00

Valve Assy, 2nd Air Reed

 

 

 

 

2

18711-42F00

Hose, 2nd Air Cleaner

 

 

 

 

3

09355-35755-600

Hose, 2nd Air Valve Vacuum

 

 

 

 

4

09401-15101

Clip

 

 

 

 

5

18531-42F00

Cover, 2nd Air Reed Valve

 

 

 

 

6

07130-06163

Bolt

 

 

 

 

7

18510-35F00

Valve Assy, Air Cut

 

 

 

 

8

18461-42F00

Hose, Air Cut Valve, Rh

 

 

 

 

9

18471-42F00

Hose, Air Cut Valve, Lh

 

 

 

 

10

18516-35F00

Cushion, Air Cut Valve Upr

 

 

 

 

11

18517-35F00

Cushion, Air Cut Valve Lwr

 

 

 

 

12

18610-42F01

Bracket, Air Cut Valve

 

 

 

 

13

07130-06103

Bolt

 

 

 

 

14

18618-42F00

Holder, Air Cut Valve

 

 

 

 

15

02112-05103

Screw

 

 

 

 

16

09401-16406

Clip

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Suzuki GSX 1400 2002 2005 User Manual

Catalogue Title:

Block No.

GSX1400K2 (GSX1400K2 E2)

FIG21

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 24 of 86

CLUTCH

 

Ref No

Part No

Description

 

 

 

1

21200-42830

Gear Assy, Primary Driven

2

09160-25037

Washer (25.1x54x2.5)

3

09263-35017

Bearing (35x40x35.8)

4

21410-42F00

Hub, Clutch Sleeve

5

21610-02F12

Cam Set, Clutch

6

21481-42F00

Bolt, Clutch Spr Support

7

21413-42F00

Spring, Clutch

8

21482-13E00

Bolt, Clutch Spring

9

21441-42F00

Plate, Clutch Drive, No.2

10

21441-42F10

Plate, Clutch Drive, No.1

10a

21472-02F10

Washer, Clutch Plate

10b

21471-02F10

Seat, Wave Washer

11

21442-42F00

Plate, Clutch Drive, No.3

12

21451-02F10

Plate, Clutch Driven

13

21462-02F10

Disk, Clutch Pressure

14

09159-24010

Nut

15

09160-25056

Washer (25x50x2.5)

16

09164-24006

Washer (24.2x35x2)

17

23110-38B00

Rod, Clutch Push, Rh

18

23111-42F00

Rod, Clutch Push, Lh

19

23117-46E00

Cover, Clutch Release Cylinder

20

02112-06103

Screw

21

23121-31E00

Piece, Clutch Push

22

23160-06B02

Cylinder, Clutch Release

23

23163-06B00

• . Cup

24

23164-05A00

• . Spring

25

59121-01A00

• . Bleeder

26

59122-01A00

• . Cap, Bleeder

27

04211-09129

Pin

28

07130-06253

Bolt

29

09160-15045

Washer (15.5x28x1)

30

09263-15003

Bearing (15x28x2)

31

09283-06007

Seal (6x34x5.5)

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 25 of 86

 

GSX1400K2 (GSX1400K2 E2)

FIG22

 

TRANSMISSION

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

 

 

1

24120-24F10

Shaft, Counter (nt:12)

 

 

 

 

2

24221-24F00

Gear, 2nd Drive (nt:16)

 

 

 

 

3

24231-24F30

Gear, 3rd & 4th Drive (nt:19/21)

 

 

 

 

4

24251-24F20

Gear, 5th Drive (nt:22)

 

 

 

 

5

24252-24F10

Bush, 5th Drive Gear

 

 

 

 

6

24261-24F20

Gear, 6th Drive (nt:24)

 

 

 

 

7

24262-24F10

Bush, 6th Drive Gear

 

 

 

 

8

09167-27003

Washer (27x36x2.5)

 

 

 

 

9

09181-27014

Washer (27x36x2.5)

 

 

 

 

10

09263-20085

Bearing. Cntr Shaft, Lh

 

 

 

 

11

09267-25012

Bearing. Cntr Shaft, Rh

 

 

 

 

12

09285-20006

Seal, Oil (20x31.7x2.7)

 

 

 

 

13

09380-27004

Circlip, 2nd Drive

 

 

 

 

14

09380-27006

Circlip, 5th /6th Drive

 

 

 

 

15

09390-62012

C Ring

 

 

 

 

16

04221-07209

Pin, Cntr Shaft Brg, Lh

 

 

 

 

17

24131-24F10

Shaft Drive

 

 

 

 

18

24311-24F10

Gear, 1st Driven (nt:35)

 

 

 

 

19

24312-24F10

Bush, 1st Driven Gear

 

 

 

 

20

24321-24F00

Gear, 2nd Driven (nt:31)

 

 

 

 

21

24322-24F10

Bush, 2nd Driven Gear

 

 

 

 

22

24331-24F00

Gear, 3rd Driven (nt:29)

 

 

 

 

23

24332-24F10

Bush, 3rd /4th Driven

 

 

 

 

24

24341-24F10

Gear, 4th Driven (nt:27)

 

 

 

 

25

24351-24F20

Gear, 5th Driven (nt:25)

 

 

 

 

26

24361-24F20

Gear, 6th Driven (nt:24)

 

 

 

 

27

09167-30008

Washer (30x38x2)

 

 

 

 

28

09167-30008

Washer (30x38x2)

 

 

 

 

29

09167-30008

Washer (30x38x2)

 

 

 

 

30

09181-20251

Washer (20x34x1.0)

 

 

 

 

31

09181-24005

Washer (24x34x1.0)

 

 

 

 

32

09263-20040

Bearing, Drive Shaft, Rh

 

 

 

 

33

09267-30011

Bearing, Drive Shaft, Lh

 

 

 

 

34

09283-42017

Seal, Oil (24x62x7)

 

 

 

 

35

09380-30009

Circlip, 2nd

 

 

 

 

36

09380-30009

Circlip, 3rd

 

 

 

 

37

09380-30009

Circlip, 4th

 

 

 

 

38

04221-07209

Pin, Drive Shaft Brg, Rh

 

 

 

 

39

08211-30405

Washer

 

 

 

 

40

27510-21A40

Sprocket, Engine (nt:18)

 

 

 

 

41

27531-42F00

Spacer, Sprocket Inner

 

 

 

 

42

27600-24F00-116

Chain Assy (rk Gb50gsvz3,116le)

 

 

 

 

43

27620-24F00

Joint Set

 

 

 

 

44

09159-20004

Nut, Engine Sprocket

 

 

 

 

45

09160-25009

Washer (25x41x3)

 

 

 

 

 

 

 

Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Catalogue Title:

Block No.

Block Title.

Suzuki Worldwide Motorcycle-ATV Page: 26 of 86

GSX1400K2 (GSX1400K2 E2)

FIG23

GEAR SHIFTING

 

 

 

 

 

 

 

 

 

 

Ref No

Part No

Description

 

 

 

 

 

 

 

 

 

1

25211-24F10

Fork, Gear Shift, N0.1

 

 

 

2

25231-24F10

Fork, Gear Shift, N0.3

 

 

 

3

25411-27A00

Shaft, Gear Shift, Fork N0.2

 

 

 

4

25411-38B01

Shaft, Gear Shift, Fork N0.1

 

 

 

5

25310-42F00

Cam, Gear Shift

 

 

 

6

04221-04089

• . Pin

 

 

 

7

25312-42F00

Bolt, Gear Shift Cam Plate

 

 

 

8

25381-42F00

Plate, Gear Shift Cam

 

 

 

9

09136-06147

Screw (6x12)

 

 

 

10

09136-06147

Screw (6x12)

 

 

 

11

09262-25006

Bearing (25x47x8)

 

 

 

12

09263-25018

Bearing (25x32x12)

 

 

 

13

25350-35F00

Stopper, Shift Cam

 

 

 

14

25355-35F01

Spring, Stopper Arm

 

 

 

15

09111-06041

Bolt (6x14.3)

 

 

 

16

08211-06141

Washer

 

 

 

17

25510-42F00

Shaft, Gear Shift

 

 

 

18

25512-13E11

Plate, Gear Shift Cam Drive

 

 

 

19

25671-35F00

Stopper, Gear Shift Arm

 

 

 

20

09160-14016

Washer (14x29x0.8)

 

 

 

21

09181-14195

Washer (14x24x1.0)

 

 

 

22

09263-14027

Bearing (14x20x12)

 

 

 

23

09283-14006

Seal, Oil (14x22x6)

 

 

 

24

09440-17009

Spring, Shift Plate Return

 

 

 

25

09444-20001

Spring, Shift Plate Return

 

 

 

26

08211-06141

Washer

 

 

 

27

08331-31146

Circlip

 

 

 

29a

25520-42E00

Arm, Gear Shift Link

 

 

 

29b

25526-47000

• . Cover, Dust

 

 

 

30

25525-07A10

Rod, Gear Shift Link

 

 

 

31

25600-42F00

Lever Assy, Gear Shift

 

 

 

32

25526-47000

• . Cover, Dust

 

 

 

33

25652-16500

• . Rubber

 

 

 

34

25617-03F00

Shaft, Gear Shift

 

 

 

35

09140-06020

Nut

 

 

 

36

09160-12011

Washer (12.5x20x1)

 

 

 

37

01500-06203

Bolt

 

 

 

38

09140-06025

Nut

 

 

 

39

08331-31126

Circlip

 

 

 

40

37730-35F10

Base Assy, Gear Shift Term

 

 

 

41

09209-05011

Contact, Gear Shift Sw

 

 

 

42

09280-26005

O Ring (d:2.4,id:26.2)

 

 

 

43

09440-04010

Spring

 

 

 

44

09106-05023

Bolt (5x16)

 

 

 

 

 

 

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