Suzuki GSX-R 1000 Service Manual: Break-in procedures
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.
- Keep to these break-in engine speed limits:
Speed limits
initial 800 km (500 miles): below 7 000 r/min
up to 1 600 km (1 000 miles): below 10 500 r/min
over 1 600 km (1 000 miles): below 13 750 r/min
- Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 13 750 r/ min at any time.
Engine coolant recommendation
Engine coolant
Use an anti-freeze/engine coolant compatible with an
aluminum radiator, mixed with distilled water only.
Water for mixing
Use distilled water only. Water other than distilled water
...
Cylinder identification
The four cylinders of this engine are identified as #1, 2, 3
and #4 cylinder, as counted from left to right (as viewed
by the rider on the seat).
...
Other materials:
Rear brake hose routing diagram
Hose clamp
: face the clamp end backward.
Stopper
: after the brake hose union has contacted
to the stopper, tighten the union bolt.
Brake pad pin
Plug
Caliper sliding pin b
Caliper sliding pin a
White marking
Yellow marking
Pass the
...
Ap sensor removal and installation
Removal
Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Disconnect the starter relay (1) from the holder.
Disconnect the coupler (2) and remove the ap
sensor (3).
Installation
Install the ap sensor in the rever ...
Camshaft sprocket
Inspect the camshaft sprocket in the following
procedures:
remove the intake and exhaust camshafts. Refer to “engine top side
disassembly” .
Inspect the teeth of each camshaft sprocket for wear
or damage.
If they are worn or damaged, replace the sprocket/
camshaft assembl ...