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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.

  1.  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

  1. 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:

Pair system inspection
Inspect pair system every 12 000 km (7 500 miles, 24 months) Inspect the pair (air supply) system periodically. Refer to pair system inspection in section 1b . Throttle valve synchronization Inspect throttle valve synchronization initially at 1 000 km (600 miles, 2 months) (e-33 only) and ...

Stp sensor removal and installation
Removal Remove the throttle body. Refer to throttle body removal and installation in section 1d (page 1d- 10).  Remove the stp sensor (1) with the special tool. Special tool : 0993011950 (torx wrench (5 mm)) Note prior to disassembly, mark the stp sensors origina ...

Conrod and crankshaft inspection
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Conrod small end I.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. Special ...

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