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Suzuki GSX-R 1000 Service Manual: Cylinder head related parts inspection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Cylinder head related parts inspection

Refer to “cylinder head disassembly and assembly” .

Cylinder head distortion

  1. Decarbonize the combustion chambers.
  2.  Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge.

    Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head.

Special tool : 09900–20803 (thickness gauge)


Cylinder head distortion service limit: 0.02 Mm (0.0008 In)

Suzuki GSX-R. Cylinder head distortion


Valve stem runout

Support the valve using v-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout exceeds the service limit, replace the valve.

Special tool (a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (v blocks)


Valve stem runout (in. & Ex.) Service limit: 0.05 Mm (0.002 In)

Suzuki GSX-R. Valve stem runout


Valve head radial runout

Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. If it measures more than the service limit, replace the valve.

Special tool (a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (v blocks)


Valve head radial runout (in. & Ex.) Service limit: 0.03 Mm (0.001 In)

Suzuki GSX-R. Valve head radial runout


Valve stem and valve face wear condition

Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one.

Suzuki GSX-R. Valve stem and valve face wear condition


Valve stem deflection

Lift the valve about 10 mm (0.39 In) from the valve seat.

Measure the valve stem deflection in two directions, “x” and “y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one.

Special tool (a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)


Valve stem deflection (in. & Ex.) Service limit: 0.25 Mm (0.010 In)

Suzuki GSX-R. Valve stem deflection


Valve stem wear

Measure the valve stem o.D. Using the micrometer. If it is out of specification, replace the valve with a new one.

If the valve stem o.D. Is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the deflection.

Special tool (a): 09900–20205 (micrometer (0 – 25
mm))

Valve stem o.D.

Standard (in.): 4.475 – 4.490 Mm (0.1762 – 0.1768 In) standard (ex.): 4.455 – 4.470 Mm (0.1754 – 0.1760 In)

Note

if valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide replacement. Refer to “valve guide replacement” .

Suzuki GSX-R. Valve stem wear


Valve spring

The force of the coil springs keep the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism.

Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace both the inner and outer springs as a set.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Valve spring free length (in. & Ex.) Service limit: inner: 30.1 Mm (1.19 In) service limit: outer: 35.3 Mm (1.39 In)

Valve spring tension (in. & Ex.) Standard: inner: 31.3 – 38.3 N (3.2 – 3.9 Kgf, 7.0 – 8.6 Lbs)/27.55 Mm (1.085 In) standard: outer: 91.3 – 105.1 N (9.3 – 10.7 Kgf, 20.5 – 23.6 Lbs)/33.05 Mm (1.301 In)

Suzuki GSX-R. Valve spring


Suzuki GSX-R. Valve spring


Suzuki GSX-R. Valve spring


Valve seat width

  1. Visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve.
  2.  Coat the valve seat with a red lead (prussian blue) and set the valve in place.
Caution

do not use lapping compound.

  1. Rotate the valve with light pressure.

Special tool (a): 09916–10911 (valve lapper set)


Suzuki GSX-R. Valve seat width


  1. Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face.

    If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter. Refer to “valve seat repair” .

Valve seat width “a” (in. & Ex.) Standard: 0.9 – 1.1 Mm (0.035 – 0.043 In)

Suzuki GSX-R. Valve seat width


Valve seat sealing condition

  1. Clean and assemble the cylinder head and valve components.
  2.  Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Refer to “valve seat repair” .
Always use
extreme caution when handling gasoline.

Suzuki GSX-R. Valve seat sealing condition


Note

after servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. Refer to “valve clearance inspection and adjustment” in section 0b .

Cylinder head disassembly and assembly
Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Caution identify the position of each removed part. Organize the parts in their respective groups (i. ...

Valve guide replacement
Remove the cylinder head. Refer to “engine top side disassembly” .  Remove the valves. Refer to “cylinder head disassembly and assembly” .  Using the valve guide remover, drive the va ...

Other materials:

Pair control solenoid valve removal and installation
Removal Lift and support the fuel tank with the prop stay. Refer to “fuel tank removal and installation” in section 1g .  Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d . Remove the pair control solenoid valve (1) along with the pair ...

Ect sensor inspection
Refer to “dtc “c15” (p0115-h/l): ect sensor circuit malfunction” in section 1a . Inspect the ect sensor in the following procedures:  remove the ect sensor. Refer to “ect sensor removal and installation” .  Connect the ect sensor (1) to the circuit tester and place it in the o ...

Gearshift shaft oil seal / bearing removal and installation
Removal Remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation” .  Remove the gearshift shaft oil seal (1). Remove the bearings (2) and (3) with the special tools. Special tool (a): 09921–20210 (bearing remover (12 mm)) ...

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