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Suzuki GSX-R 1000 Service Manual: Cylinder inspection

Refer to “engine top side disassembly” .

Refer to “engine top side assembly” .

Cylinder distortion

Check the gasket surface of the cylinder for distortion.

Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the crankcase set.

Special tool : 09900–20803 (thickness gauge)

Cylinder distortion service limit: 0.02 Mm (0.0008 In)

Suzuki GSX-R. Cylinder distortion


Cylinder bore

Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston.

The remaining cylinders must also be rebored accordingly; otherwise, the imbalance might cause excessive vibration.

Special tool (a): 09900–20530 (cylinder gauge set)

Cylinder bore standard: 74.500 – 74.515 Mm (2.9331 – 2.9337 In)

Suzuki GSX-R. Cylinder bore


Suzuki GSX-R. Cylinder bore


Piston-to-cylinder clearance

Refer to “piston and piston ring inspection” (page 1d- 71).

Engine bottom side assembly
Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: Note apply engine oil to each running and sliding part before reassembling. ...

Piston ring removal and installation
Removal Remove the piston. Refer to “engine bottom side disassembly” .  Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove i ...

Other materials:

Radiator reservoir tank removal and installation
Removal Remove the right side cowling. Refer to “exterior parts removal and installation” in section 9d .  Disconnect the reservoir tank inlet hose (1) from the reservoir tank (2) and drain the engine coolant.  Remove the reservoir tank (2). Disconnect the reservoir tank ove ...

Clutch cable removal and installation
Removal Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Disconnect the clutch cable from the clutch lever. Refer to “handlebar removal and installation” in section 6b .  Remove the clutch cable as shown in the throttle cable ro ...

Cam chain guide / cam chain tensioner removal and installation
Removal Remove the cylinder head cover. Refer to “engine top side disassembly” .  Remove the cam chain guide no. 2 (1). Remove the cylinder head. Refer to “engine top side disassembly”  and “engine bottom side disassembly” .  Remove the starter clutch. Refer to “s ...

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