GS/GSX/GSX-R#095: GSX-R600 750 Fuel Pump Gasket RECALL
Contents
1. for fuel tank draining and removal procedures Remove the fuel supply hose from the fuel petcock and connect a hose that will drain the fuel into a suitable container Use the Suzuki special tool Vacuum Pump PN 09917 47910 to apply negative pressure to the vacuum port of the petcock This will open the petcock and allow the fuel to drain PARTS ORDERING YOU WILL BE RESPONSIBLE FOR ORDERING THE FUEL PUMP GASKET FOR YOUR CUSTOMER S MOTORCYCLE You will need to use the special FAX order form on pages 16 and 17 of this service bulletin to order the redesigned parts A WARNING STORING A MOTORCYCLE WITH DRIPPING GASOLINE IN AN AREA WITH AN IGNITION SOURCE CAN LEAD TO A FIRE AS SOON AS A MOTORCYCLE COMES TO YOUR DEALERSHIP FOR RECALL SERVICE DRAIN THE GASOLINE FROM THE FUEL TANK DO THIS IMMEDIATELY EVEN IF YOU DO NOT HAVE THE PARTS TO PERFORM THE RECALL REPAIRS Whether the tank is leaking or not or is already drained Suzuki suggests you store the motorcycle in a well ventilated secure area without potential ignition sources Under some conditions leaking may occur without prior warning Potential fire ignition sources include furnaces welders bench grinders computers and other electrical appliances and power outlets Do not smoke near the motorcycle DO NOT TIGHTEN THE ORIGINAL FUEL PUMP MOUNTING BOLTS TO TRY TO RESOLVE A FUEL LEAK THESE ARE LOW TORQUE BOLTS THAT MUST BE TIGHTENED IN A SPECIFIC SEQUENCE OVERTIGHTENING2. SUZUKI Service Bulletin REVISED 7 6 98 BULLETIN NO GS GSX GSX R 95 DATE 7 2 98 SAFETY RECALL CAMPAIGN GSX R6O00V amp GSX R750T V FUEL PUMP GASKET MODELS 1996 GSX R750T 1997 GSX R600V amp 1997 GSX R750V SUBJECT RECALL CAMPAIGN FUEL PUMP GASKET REFERENCE Dealer and customer letters attached NOTICE Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 1996 GSX R 50T 1997 GSX R600V amp 1997 GSX R 50V model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles STOP DELIVERY OF 1996 GSX R750T 1997 GSX R600V amp 1997 GSX R 50V MOTORCYCLES IMMEDIATELY Effective immediately DO NOT DELIVER a GSX R750T GSX R600V or GSX R750V to customer until you complete the recall service described in this service bulletin Suzuki Motor Corporation has determined that the gasket between the fuel tank and the fuel pump mounting plate can lose its ability to provide a tight seal allowing fuel to drip from the gasket In the presence of an ignition source leaked fuel can cause a fire Fire can cause personal injury or death property damage or damage to the motorcycle Due to the serious nature of this situation Suzuki requires that you ORDER THE REDESIGNED FUEL PUMP GASKET AND PERFORM THE RECALL SERVICE AS QUICKLY AS POSSIBLE Join with us in promoting the safe use of Suzuki products Fuel Pump Fuel Pump Gasket Fuel Pump
3. MILEAGE HOURS Request Form PURCHASE DATE DATE OF EXPIRATION Hometown 91111 75 22 98 Tero E EA E E 32 eo Guu 1 Fuel Pump Gasket ADDITIONAL PART M NUMBERS USED PARTS DESCRIPTION OPERATION NUMBER CODE 41 D H 9 9 9 gt 2 aren E 71698 7 16 98 lt _ lt Phil Evany T S _4 o RECEIVED PROCESSED aaa O 1 Replace tuet pump gasket tuat tank per Service Bulletin GSX R 95_ TT DEALER COPY Continued p 14 GSX R600V amp GSX R750T V FUEL SUZUKI PUMP GASKET SET RECALL FAX ORDER FORM Dealer __ Name Telephone _ FAX __ Description Part Number Quantity Fuel Pump Gasket Set 99103 11135 List the frame numbers for both CUSTOMER and UNSOLD motorcycles Check Model Last Nine Digits First Name Last Name 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN eee Customer 600 750 VIN ITITI Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Ce Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer _ 750 LLLL LTT T customer 600 _ 750 VIN C
4. THE BOLTS OR TIGHTENING THEM IN THE WRONG SEQUENCE CAN INCREASE THE POSSIBILITY OF FUEL LEAKAGE Continued p PARTS ORDERING PROCEDURE IMPORTANT SCAT AND MAILED PARTS ORDERS CANNOT BE ACCEPTED Please make a copy of the FAX order form and legibly write your dealership name Suzuki dealer number and telephone number Write the quantity of fuel pump gasket sets you require Write each motorcycle s VIN and customer name If the motorcycle is not sold please write UNSOLD on the customer line If there is not enough space for customer names use a second copy of the form Once complete FAX the order form to Suzuki This FAX ordering method is the only way to order recall service parts REMEMBER SCAT and mailed parts orders cannot be accepted RECALL SERVICE PARTS ORDER FAX LINE 714 528 3090 USE THE ATTACHED ORDER FORM PARTS SHIPMENT DATES Parts will be shipped to you via UPS 3 Day Shipment freight prepaid net 90 days The earliest parts can arrive at your dealership is July 13 1998 Suzuki anticipates all parts will be shipped by August 15 1998 Parts orders will be shipped in the order in which they are received Place your fax orders as soon as possible to prevent any delays in performing the recall service for your customers Recall service parts can not be automatically shipped by Suzuki You must place an order using a FAX order form as instructed above to receive parts RECALL SERVICE PARTS NUMBERS All p
5. completion of this recall campaign depends on your efforts Itis very important that your dealership contact each customer have them inspect their motorcycle immediately and follow the instructions that you give them You must order the correct parts perform the recall service and complete a Campaign Completion Card or Warranty Request Form within the shortest possible time It is your responsibility to order parts and perform the recall service any affected motorcycle brought to your dealership even if your dealership did not originally sell the motorcycle All recall campaign service is to be done at no cost to the customer for parts and labor Incidental costs your customers may incur are not normally covered However if you have a customer with special needs contact your Technical Service Manager to discuss possible solutions CUSTOMER SATISFACTION Please be sure that all dealership personnel are familiar with the campaign parts ordering and recall service procedures Only your conscientious action at the dealership level can lead to a successful campaign conclusion Your customers may have had to bring their GSX R motorcycles in for other modification programs or repairs in the past Please remind your staff to be sympathetic and sensitive to your customers feelings Please extend Suzuki s apologies for the inconvenience that this repair may cause them We apologize for any inconvenience this recall campaign may cause you or y
6. fuel filler water drain hose from the fuel tank Disconnect the fuel hose the vacuum hose from the petcock and the fuel pump lead wire connector NOTE On the California model it is necessary to disconnect the fuel surge hose from the roll over valve on the fuel tank Fig 14 amp 15 Connect a hose to the fuel nipple on the petcock Route the hose to a suitable Negative pressure to petcock 1 9 psi container to catch the draining fuel Use aclean 13 3kPa 0 133kq cem2 container so you can reuse the drained fuel ca 9 Connect a vacuum pump to the vacuum port of the petcock Apply 1 9 psi of negative pres sure to open the fuel petcock Do not apply high negative pressure as you can damage the vacuum valve in the petcock Vacuum Pump with Gauge PN09917 47910 Black Fig 16 Connect the positive terminal of a12V with motorcycle battery to the Yellow with Red White tracer wire of the fuel pump connector Con nect the negative terminal to the Black with White tracer wire This will operate the pump and drain the fuel tank The pump speed will audibly increase as the tank empties of fuel Fuel Pump Connector Gasoline is highly flammable explosive and toxic Keep heat sparks and flame away Continued p After the fuel draining is complete disconnect the hoses and wire connector from the battery Remove the prop stand and gently lower the fuel tank down Fig 77 Remove the rear fuel tank mo
7. the fuel drained from the motorcycle Your cooperation is also needed in transporting motorcycles to your dealership in situations where the customer is unable or uncomfortable to do so If a customer asks you to provide fuel draining service or motorcycle transportation prepare a cost estimate and contact your Technical Service Manager for authorization before providing these services DRAIN FUEL FROM THE MOTORCYCLE As soon as a customer brings the motorcycle to your dealership drain the gasoline from the fuel tank Do this immediately even if you do not have the parts to perform the recall service Follow the instructions warnings and cautions in section 4 of the GSX R6OOV service manual PN 99500 35060 03 or the GSX R 50T V service manual 99500 37080 for fuel tank draining and removal procedures Remove the fuel supply hose from the fuel petcock and connect a hose that will drain the fuel into a suitable container Use the Suzuki special tool Vacuum Pump PN 09917 47910 to apply negative pressure to the vacuum port of the petcock This will open the petcock and allow the fuel to drain STORING A MOTORCYCLE WITH DRIPPING GASOLINE IN AN AREA WITH AN IGNITION SOURCE CAN LEAD TO A FIRE AS SOON AS A MOTORCYCLE COMES TO YOUR DEALERSHIP FOR RECALL SERVICE DRAIN THE GASOLINE FROM THE FUEL TANK DO THIS IMMEDIATELY EVEN IF YOU DO NOT HAVE THE PARTS TO PERFORM THE RECALL REPAIRS Whether the tank is leaking or not or is alr
8. 99500 37080 O3E for hose routing information Remove the prop stand and gently lower the fuel tank down to the frame Mounting Bolt Tightening Sequence 25 71 Mounting Bolt Torque Steps amp Specifications 7 Initial torque 21 6lb in 2 5N m O 25kgf m 2 amp 3 Final torque 34 8lb in 4 0 4kgf m 71 Rear tank mount bolts 21 b ft 29N m 2 9kgf m Continued gt 11 Fig 28 Fill the fuel tank with at least one gallon of gasoline and wait for about five minutes Check for any fuel leakage from the fuel tank fuel pump gasket or any hose Repair any fuel leak immediately DO NOT test ride or deliver the motorcycle to the customer if a fuel leak is present Reinstall the front fuel tank mounting bolts and torque them to 7 0 lb ft Reinstall the rear frame covers and the rider and passenger seats 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 recall service ADVISE THE CUSTOMER OF THE FUEL LEVEL WHEN YOU DELIVER THE MOTORCYCLE RIDE THE MOTORCYCLE To ensure customer satisfaction Suzuki sug gests you ride the motorcycle several miles to make sure there are no fuel leaks and all the controls and the motorcycle operate cor rectly Correct any recall service related problems before delivering the motorcycle to the cus tomer APPLY OK STICKER Fig 29 After checkin
9. ACTION You will install a redesigned fuel pump gasket on the fuel tank Unlike the TL1O00SV W recall service you WILL NOT replace the fuel tank Instructions for this procedure begin on page 5 of this bulletin Due to the serious nature of this situation Suzuki requires that you ORDER THE REDESIGNED FUEL PUMP GASKET AND PERFORM THE RECALL SERVICE AS QUICKLY AS POSSIBLE Join with us in promoting the safe use of Suzuki products FUEL DRAINING amp MOTORCYCLE TRANSPORTATION In the notification letter customers have been instructed to inspect their motorcycle and to not operate the motorcycle if a gasoline leak is present Your complete cooperation is needed if the customer asks to have the fuel drained from the motorcycle Your cooperation is also needed in transporting motorcycles to your dealership in situations where the customer is unable or uncomfortable to do so Ifa customer asks you to provide fuel draining service or motorcycle transportation prepare a cost estimate and contact your Technical Service Manager for authorization before providing these services DRAIN FUEL FROM THE MOTORCYCLE As soon as a customer brings a motorcycle to your dealership drain the gasoline from the fuel tank Do this immediately even if you do not have the parts to perform the recall service Follow the instructions warnings and cautions in section 4 of the GSX R6OOV service manual PN 99500 35060 03E or the GSX R 50T V service manual 99500 37080
10. E Move your motorcycle to a well ventilated area away from flame sparks and other potential ignition sources Potential fire ignition sources include furnaces water heaters clothes washers and dryers and other electrical appliances and power outlets Inspect your motorcycle for any signs of dripping or seeping gasoline or the smell of gasoline Begin your inspection at the rear underside of the fuel tank This is where the fuel pump is mounted into the fuel tank If there is any evidence of gasoline dripping seeping or the smell of gasoline contact your authorized Suzuki dealer to have the fuel drained from your motorcycle at the earliest opportunity Whether the tank 15 leaking or not store your motorcycle in a well ventilated secure area without potential ignition sources Under some conditions leaking may occur without prior warning Gasoline is flammable hazardous and toxic Keep children and pets away from your motorcycle DO NOT TIGHTEN THE FUEL PUMP MOUNTING BOLTS THESE ARE LOW TORQUE BOLTS THAT MUST BE TIGHTENED IN A SPECIFIC SEQUENCE OVERTIGHTENING THE BOLTS OR TIGHTENING THEM IN THE WRONG SEQUENCE WILL INCREASE THE POSSIBILITY OF FUEL LEAKAGE Continued gt 22 A WARNING RIDING A MOTORCYCLE WITH DRIPPING GASOLINE CAN LEAD TO A FIRE IF AN IGNITION SOURCE IS PRESENT UNDER SOME CONDITIONS LEAKING MAY OCCUR WITHOUT PRIOR WARNING SUZUKI RECOMMENDS THAT YOU DO NOT RIDE YOUR MOTORCYCLE UNTIL
11. Mounting Plate Fuel Tank 1 Continued p CUSTOMER NOTIFICATION For motorcycles that have already been delivered to customers perform the recall service as promptly as possible Attached is a letter being sent to all owners of affected motorcycles about whom we have information This letter was mailed on June 29 1998 If your dealership has sold a GSX R6O0OV ora GSX 50T V to a customer but not yet mailed us the Sales In Service Registration card or submitted SCAT entry send the sales information to American Suzuki AT ONCE We will send the customer an owner notification letter when we receive the sales information from your dealership NOTICE Please PHONE all of your customers and inform them of the recall campaign and the need to inspect their motorcycles immediately Advise the customer to move the motorcycle to a well ventilated area away from flame sparks and other potential ignition sources inspect the motorcycle for any signs of dripping or seeping gasoline or the smell of gasoline begin the inspection at the rear underside of the fuel tank This is where the fuel pump is mounted into the fuel tank If there is any evidence of gasoline dripping seeping or the smell of gasoline instruct the customer to contact your dealership to have the fuel drained from the motorcycle at the earliest opportunity Tell the customer not to ride the motorcycle until the recall service is performed since o
12. THE RECALL SERVICE HAS BEEN PERFORMED Inspect your motorcycle for signs of dripping or seeping gasoline or the smell of gasoline Do not ride your motorcycle if there is any evidence of gasoline dripping or seeping or the smell of gasoline Contact your authorized Suzuki dealer to have the fuel drained from your motorcycle at the earliest opportunity Store your motorcycle as outlined on the previous page If there is evidence of gasoline dripping or seeping and there is no smell of gasoline you can elect to ride your motorcycle to your dealer for the recall service Have the recall service performed as soon as possible DO NOT TIGHTEN THE FUEL PUMP MOUNTING BOLTS THESE ARE LOW TORQUE BOLTS THAT MUST BE TIGHTENED IN A SPECIFIC SEQUENCE OVERTIGHTENING THE BOLTS OR TIGHTENING THEM IN THE WRONG SEQUENCE WILL INCREASE THE POSSIBILITY OF FUEL LEAKAGE TAKE THE MOTORCYCLE TO YOUR DEALER there 15 any evidence of gasoline dripping or seeping transport your motorcycle to your authorized Suzuki dealer using an open trailer or truck Do not use an enclosed vehicle such as a van since gasoline fumes are hazardous and toxic Take care securing and protecting your motorcycle for transportation Suzuki cannot be responsible for damage caused by improper transportation methods If you cannot arrange for transportation of your motorcycle or want the fuel drained from your motorcycle contact the service manager or own
13. al allowing fuel to drip from the gasket In the presence of an ignition source leaked fuel can cause a fire Fire cause personal injury or death property damage or damage to the motorcycle Due to the serious nature of this situation Suzuki requires that you ORDER THE REDESIGNED FUEL PUMP GASKET AND PERFORM THE RECALL SERVICE AS QUICKLY AS POSSIBLE Join with us in promoting the safe use of Suzuki products AFFECTED UNITS All 1996 GSX R7 750T 1997 GSX R6O00V 1997 GSX R 50V models are affected CUSTOMER NOTIFICATION For motorcycles that have already been delivered to customers perform the recall service as promptly as possible Attached is a letter being sent to all owners of affected motorcycles about whom we have information This letter will be mailed June 30 1998 NOTICE Please PHONE all of your customers and inform them of the recall campaign and the need to inspect their motorcycles immediately Advise the customer to move the motorcycle to a well ventilated area away from flame sparks and other potential ignition sources inspect the motorcycle for any signs of dripping or seeping gasoline or the smell of gasoline begin the inspection at the rear underside of the fuel tank This is where the fuel pump is mounted into the fuel tank If there is any evidence of gasoline dripping seeping or the smell of gasoline instruct the customer to contact your dealership to have the fuel drained from the motorc
14. all service Call your dealer if you have any questions If you have any difficulty having the recall service performed to your motorcycle you may contact American Suzuki Customer Service Department for assistance at 714 996 7040 ext 660 If you believe that 1 Suzuki or your Suzuki dealer has failed to or is unable to perform the recall service without charge or 2 you believe Suzuki has failed to or is unable to perform the recall service to your vehicle within 60 days after you first brought your vehicle to your Suzuki dealer after July 13 1998 you may submit a complaint to the Administrator National Highway Traffic Safety Administration 400 Seventh Street S W Washington D C 20590 or call the toll free Auto Safety Hotline at 800 424 9393 Washington DC area residents may call 366 0123 If you no longer own a GSX R6OOV GSX R 50T or GSX R750V or never owned please fill out and mail the enclosed postage paid pre addressed reply card If you have sold your GSX R please fill in the name and address of the person to whom you sold your motorcycle This will help us notify the new owner about this recall campaign We thank you for your prompt attention to completing this recall service on your Suzuki motorcycle We apologize for any inconvenience this recall campaign causes you Your safety satisfaction and riding pleasure are priorities for Suzuki Sincerely American Suzuki Motor Corporation 24
15. arts needed to complete the recall service are included when you order the fuel pump gasket set Description Part Number Dir Price Fuel Pump Gasket Set 99103 11135 13 00 The following items are included with each fuel pump gasket order Description Quantity Fuel Pump Gasket Fuel Pump Gasket Plate Campaign Completion Card OK Identification Label Fuel Pump Mounting Bolts PARTS RETURN or ADDITIONAL PARTS If you require additional parts return authorization have any other questions about this recall service contact TECH LINE or your Technical Service Manager Continued p 4 REPAIR PROCEDURE Tools required 7 Suzuki service stand or equivalent stand 2 12mm socket and ratchet 3 8mm socket and ratchet 4 12mm wrench 5 4mm Allen wrench 6 6mm Allen wrench 7 2 Phillips screwdriver 8 3 Phillips screwdriver 9 Pliers 70 Torque wrench 77 Container for drained fuel 12 Vacuum Pump Fig 7 Place the motorcycle on the Suzuki service stand or equivalent Service Stand PN 99950 70042 RAC PN 99950 70041 PRO Fig 2 Turn the ignition key clockwise in the left hand seat lock to unlock and remove the pas senger seat or tail cowl Fig 3 Fig 4 Pull the rear edges of the riders seat up and use a 6mm allen wrench to remove the two bolts that hold the seat to the sub frame Fig 5 Pull back and turn the seat to the side to lift it of
16. dealership should be notified of this information Service Parts Sales Accessories American Suzuki Motor Corporation Technical Service Department Motorcycle Division 13 RECALL CAMPAIGN COMPLETION CARD EXAMPLE SUZUKI DEALER CAMPAIGN COMPLETION CARD 2032 GSX R600V GSX R750T V FUEL PUMP GASKET SET 11213415 6 2033 TL1000SV W FUEL PUMP GASKET SET AND TANK DEALER CAMPAIGN DESCRIPTION 7 TL1000SV TL1000SW LS DATE COMPLETED MODEL ee ONE CONTROLISEQ MIF KNOWN PLEASE CHECK THE CORRECT BOX MAIL THIS CARD TO MODIFICATION PERFORMED AMERICAN SUZUKI 1010 NOT WISH THIS MODIFICATION TO BE PREFORMED MOTOR CORPORATION O THIS PRODUCT HAS BEEN LOST STOLEN OR DESTROYED PLEASE ATTACH M C WARRANTY DEPT 4151611 EXPLANATION P O BOX 1100 BREA CA 92822 1100 CLAIM CUSTOMER SIGNATURE DATE X Brad Smith 7 8 AB DEALER SIGNATURE DATE X Phil Evany 7 18 98 RECALL CAMPAIGN WARRANTY REQUEST FORM EXAMPLE IMPORTANT PLEASE LIST ONLY ONE 1 DEFECT PER FORM SUZUKI Wa r ra nty Request REFER TO YOUR WARRANTY MANUAL FOR COMPLETE INSTRUCTIONS TYPE OR PRINT CLEARLY DO NOT WRITE IN THE BLUE SPACES co 10 11213 56 1j213j415 6 7 fP br DEFECT DATE REPAIR DATE S R 7 5 OV OV 2 1 0 0 0 0 0 Warranty Request Type MONTH DATE ___ YEAR Cala 07 18 98 onceale rate enra Brad Smith ae Y
17. eady drained Suzuki suggests you store the motorcycle in a well ventilated secure area without potential ignition sources Under some conditions leaking may occur without prior warning Potential fire ignition sources include furnaces welders bench grinders computers and other electrical appliances and power outlets Do not smoke near the motorcycle DO NOT TIGHTEN THE ORIGINAL FUEL PUMP MOUNTING BOLTS TO TRY TO RESOLVE A FUEL LEAK THESE ARE LOW TORQUE BOLTS THAT MUST BE TIGHTENED IN A SPECIFIC SEQUENCE OVERTIGHTENING THE BOLTS OR TIGHTENING THEM IN THE WRONG SEQUENCE CAN INCREASE THE POSSIBILITY OF FUEL LEAKAGE Continued gt 20 REPAIR PROCEDURES service bulletin GS GSX GSX R 95 will contain instructions on how to replace the fuel pump gasket PARTS ORDERING amp PARTS SHIPPING YOU WILL BE RESPONSIBLE FOR ORDERING THE REDESIGNED FUEL PUMP GASKET PARTS FOR YOUR CUSTOMER S MOTORCYCLE You will need to use the special FAX order form included in the service bulletin to order the recall service parts Parts will be shipped to you via UPS 3 Day Shipment freight prepaid net 90 days The earliest parts can arrive at your dealership is July 13 1998 Suzuki anticipates all parts will be shipped by August 15 1998 Parts orders will be shipped in the order which they are received Place your fax orders as soon as possible to prevent any delays in performing the recall service for your customers IMPORTANT Successful
18. er of your authorized Suzuki dealership for assistance Your Suzuki dealer may be able to provide assistance in draining the fuel or transporting your motorcycle to the dealership for the recall service if you have no method to transport the motorcycle yourself If there is no evidence of gasoline dripping or seeping and there is no smell of gasoline you can elect to ride your motorcycle to your dealer for the recall service PARTS amp REPAIR INFORMATION Your Suzuki dealer will need to order recall service parts for your motorcycle Call your Suzuki dealer to schedule an appointment for the recall service Your dealer can then place the order for your recall service parts The earliest date parts can be at your Suzuki dealer is July 13 1998 Suzuki anticipates all parts will be shipped by August 15 1998 If you Cannot contact the Suzuki dealer who sold you your motorcycle call toll free 1 800 255 2550 for your nearest Suzuki motorcycle dealer It will take your dealer about an hour to drain the fuel tank and install the redesigned fuel pump gasket Because of the time required to do this type of repair in most instances you will need to leave your motorcycle at the dealership and pick it up at a later date Ask your dealer about your motorcycle s down time as he may be able to perform the recall service while you wait Continued gt 23 Remember that your Suzuki dealer has specific and complete instructions regarding this rec
19. et gasket plate or tank as you install the fuel pump Turn the new fuel pump mounting bolts lightly in by hand until they are seated Fuel pump mounting plate Continued gt 10 Fig 24 The mounting bolts are torqued in specific tightening sequence Fig 25 Perform the tightening sequence in three steps OTorque the mounting bolts to the initial torque 1 8 lb ft following the cor rect sequence Torque the bolts to final torque 2 9 lb ft following the correct se quence Torque the bolts once again to the final torque 2 9 b ft in the correct sequence NOTE 1 4 drive torque wrench calibrated in works well the low torque mounting bolts Failure to follow the fuel pump mounting bolt torque specifications and tightening sequence could cause improper gasket sealing and fuel leakage DO NOT OVER TIGHTEN THE MOUNTING BOLTS Fig 26 Set the fuel tank on the motorcycle Install and torque the rear fuel tank mounting bolts to 21lb ft Fig 27 Lift and support the fuel tank with the prop stand Connect the fuel hose the vacuum hose and fuel filler water drain hose Route the hoses properly and make sure all the hose clamps are in place and secured NOTE Reconnect the fuel surge hose to the roll over valve on California specification models NOTE Refer to sections 8 and 9 of the GSX R600 service manual PN 99500 35060 03 or GSX R7 50 service manual PN
20. f the motorcycle ly ic J g i 4 f eo Continued p The fuel tank will have to be removed to install the new fuel pump gasket Remove the frame side covers to provide access to the rear fuel tank mount Fig 6 Remove the right hand and left hand side frame cover screws with a 3 phillips screwdriver Fig 7 Remove the right and left upper frame cover screws with a phillips screwdriver Remove the passenger seat cushions spacers and rubber washer Fig 8 Usea 2 phillips screwdriver to remove the two frame cover screws on the rear underside of the covers near the tail lamp Fig 9 Usea 2 phillips screwdriver to remove the two center frame cover screws careful as the frame covers will come apart and off the motorcycle when these screws are removed Remove the clip nuts from the covers so they will not get lost Continued p Fig 70 Remove the two fuel tank mount bolts with a 4mm Allen wrench Fig 17 Un clip the tool kit strap on the rear fender Fig 72 Set the tool kit aside and lift the prop stand out of the groove in the fender Fig 13 Lift the tank up and set the prop stand in place between the steering stem and the tabs on the front of the tank Continued p Fuel Pump Fuel Pump A gt Petcock A Fuel Pump o Connector Fuel Container 12 volt motorcycle battery Fig 14 Disconnect the
21. g and ensuring the recall service was performed correctly apply the OK sticker to the right hand frame rail The OK sticker provides identification that the recall service has been performed on the motorcycle NOTE Place the sticker behind the fairing cowl just below the top edge This location will not distract from the motorcycle s appearance yet can be found during a close inspection TAG amp SAVE OLD PARTS Complete the vehicle and repair information on warranty parts tag PN 99923 09822 003 Attach the tag to the old recall service parts Hold the parts indefinitely until inspection by your Technical Service Manager 12 WARRANTY REIMBURSEMENT SCAT WARRANTY REQUESTS At this time Recall Campaign warranty requests submitted via SCAT cannot be accepted PARTS amp LABOR REIMBURSEMENT You will be reimbursed 0 7 hour labor 100 for parts cost for each recall service performed CAMPAIGN COMPLETION CARD For your convenience a Dealer Campaign Completion Card is included with each fuel pump gasket set Fill out the card completely for each GSX R motorcycle repaired following the example on page 15 Circle the model you performed the service on Have the customer sign the card and send it to the American Suzuki Warranty Dept in Brea California as you would your regular warranty claim requests WARRANTY REQUEST FORM Ifa Campaign Completion Card is not available or if additional parts or labor credit i
22. move the fuel pump and gasket arn Clean the fuel pump gasket surface Continued p ORIGINAL Original one piece Fig 27 amp 22 The original one piece fuel pump gasket will be replaced by a new lip style gasket and fuel pump gasket plate The new fuel pump gasket will fit inside of the plate The plate ensures the gasket will be com pressed the proper amount when the fuel pump is mounted to the fuel tank Flange style fuel pump mounting bolts replace the original bolts New lip style gasket Fig 23 The white directional dot on the gasket must face forward and towards the fuel pump mounting plate away from the fuel tank Place the gasket plate on the fuel tank make sure the holes align with the bolt holes in the fuel tank Place the gasket inside the plate and lightly press the gasket into the New groove on the tank using your fingers only to pump avoid damaging the gasket Make sure the gasket plate fuel longer lip of the gasket 15 set into the fuel tank mounting bolt groove properly NOTE Make sure the mounting bolt holes in the fuel tank and gasket plate align with the relieved edge of the gasket before attempting to install White the fuel pump directional Fuel pump Gently slide the fuel pump into the fuel tank Take care to not disturb the fuel pump gasket A CAUTION Be careful not to catch or damage the fuel strainer on the fuel pump gask
23. nly you know the identity of these customers you must immediately notify these customers of the recall campaign Please phone all of these customers and inform them of the need to have the recall service performed and explain the situation as described in the notices and warnings this bulletin NOTICE Whether the tank is leaking or not advise the customer to store the motorcycle in a well ventilated secure area without potential ignition sources Under some conditions leaking may occur without prior warning Have the customer check the motorcycle daily for any signs of gasoline dripping seeping or smell of gasoline until the recall service is completed CUSTOMER LETTER Attached to this bulletin is a copy of acustomer letter sent June 29 1998 to registered owners of 5 6 or GSX750T V motorcycles The letter explains the reason for this recall Campaign and stresses the need to make an appointment with an authorized Suzuki dealer to have the recall service performed AFFECTED UNITS All 1996 GSX R 50T 1997 GSX R600V and GSX R 750V models affected UNITS OUT OF REACH If you are aware of GSX R6O0O0V or GSX750T V motorcycles which are scrapped or outside of the United States notify Suzuki in writing Please include vehicle VIN and location information on your dealership letterhead Send this information to the American Suzuki Warranty Dept in Brea California Continued p 2 CORRECTIVE
24. our customers Thank you for your cooperation in conducting this very important campaign for your customers safety sincerely American Suzuki Motor Corporation Continued gt 21 SUZUKI AMERICAN SUZUKI MOTOR CORPORATION MOTORCYCLE June 29 1998 SAFETY RECALL NOTICE GSX R600V GSX R750T amp GSX R750V FUEL GASKET Dear Suzuki Owner This notice is sent to you accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists all 1996 GSX R 50T 1997 GSX R60O0V and 1997 GSX R 50V model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles According to our records you are the owner of one of these motorcycles Suzuki Motor Corporation has determined that the gasket between the fuel tank and the fuel pump mounting plate can lose its ability to provide a tight seal allowing fuel to drip from the gasket In the presence of an ignition source leaked fuel can cause a fire Fire can cause personal injury or death property damage or damage to the motorcycle Your authorized Suzuki dealer will replace the fuel pump gasket of your motorcycle s fuel tank with a redesigned version This repair will be done at no cost to you for parts and labor A WARNING STORING A MOTORCYCLE WITH DRIPPING GASOLINE IN AN AREA WITH AN IGNITION SOURCE CAN LEAD TO A FIR
25. s required use a Warranty Request Form to get reimbursed for the recall service Fill out a Warranty Request Form completely for each motorcycle repaired following the example on page 15 When filling out the Warranty Request Form be sure to include the following information CAUSAL PAM a 99103 11135 CAUSAL PART DESCRIPTION Fuel Pump Gasket OVANTE Y ee er errr ett 1 COMPLAINT CODES 99 DEFECT CODE U5 OPERA ION CODE DH9999 LABOR oaeee 0 7 Cross off the form s request number write in the campaign number 2032 Have the customer sign the request and send it to the American Suzuki Warranty Dept in Brea California as you would your regular warranty claim requests CUSTOMER SATISFACTION When delivering a motorcycle to the customer review the service performed If you have acustomer witha special request contact your Technical Service Manager for consideration We apologize for any inconvenience this recall campaign may cause you or your customers Please be sure that all dealership personnel are familiar with the parts ordering and recall service procedure Only your conscientious action at the dealership level can lead to a successful campaign conclusion Thank you for your cooperation in conducting this very important campaign for your customer s safety AFFECTED DEPARTMENTS The following departments in your
26. unting bolts and lift the fuel tank off the motorcycle Set the removed fuel tank upside down appropriately protected stand or bench top A CAUTION Be careful not to damage the fuel tank Place the fuel tank on an appropriately protected surface Use protective sheets or cloths free of gas oil or other materials that could damage the paint finish SUGGESTION Fig 18 You may construct a rectangular wood frame using 2 x 4 or 2 x 6 studs to support the inverted fuel tank on your work bench Completely cover the frame with a soft towel shipping blanket or similar protective cloth to protect the fuel tank finish Fig 79 Remove the 8 fuel pump mounting bolts and lift the fuel pump and fuel pump gasket from the tank A CAUTION Be careful not to damage the removed fuel pump The fuel pump will be reinstalled in the fuel tank Drain any residual fuel from the fuel tank through the hole from which the fuel pump was removed Drain the fuel into a suitable con tainer using a large funnel Use a clean con tainer so you can reuse the fuel Gasoline is highly flammable explosive and toxic Keep heat sparks and flame away Fig 20 Clean the fuel pump gasket surface and the fuel pump bolt mounting holes with alcohol or another non petroleum based sol vent Make sure these surfaces are completely dry Approximate size Yes Remove cs bolts and carefully re
27. ustomer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN Customer 600 750 VIN ITITI Customer 600 750 VIN Customer 600 750 VIN TT Customer Use a second copy of this order form if needed FUEL PUMP GASKET SET FAX LINE 714 528 3090 a he SUZUKI AMERICAN SUZUKI MOTOR CORPORATION June 26 1998 SAFETY RECALL CAMPAIGN GSX RGOOV GSX R750T amp GSX R750V FUEL PUMP GASKET Dear Suzuki Dealer This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 1997 GSX R600V 1996 GSX R 50T and 1997 GSX R 50V model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles STOP DELIVERY OF GSX R600V GSX R7 50T amp GSX R750V MOTORCYCLES IMMEDIATELY Effective immediately DO NOT DELIVER GSX R600V GSX R7 50T GSX R750V to a customer until you complete the repair procedures described the related service bulletin that will be sent to your dealership Suzuki Motor Corporation has determined that the gasket between the fuel tank and the fuel pump mounting plate can lose its ability to provide a tight se
28. ycle at the earliest opportunity Tell the customer not to ride the motorcycle until the recall service is performed Continued gt 19 Whether the tank 15 leaking or not advise the customer to store the motorcycle a well ventilated secure area without potential ignition sources Under some conditions leaking may occur without prior warning Have the customer check the motorcycle daily for any signs of gasoline dripping seeping or smell of gasoline until the recall service is completed CUSTOMER NOTIFICATION If your dealership has sold a GSX R60O0V GSX R 50T GSX R 50V to a customer but not yet mailed us the Sales In Service Registration card or submitted a SCAT entry send the sales information to American Suzuki AT ONCE We will send the customer an owner notification letter when we receive the sales information from your dealership Since only you know the identity of these customers you must immediately notify these customers of the recall campaign Please phone all of these customers and inform them of the need to have the recall service performed and explain the situation as described in the notices above and on the previous page FUEL DRAINING amp MOTORCYCLE TRANSPORTATION In the notification letter customers have been instructed to inspect their motorcycle and to not operate the motorcycle if a gasoline leak is present Your complete cooperation 15 needed if the customer asks to have
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