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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 : 0990020803 (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): 0990020530 (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:

Rear shock absorber disposal
Refer to rear shock absorber removal and installation . The rear shock absorber unit contains high-pressure nitrogen gas. Mishandling can cause explosion.  Keep away from fire and heat. High gas pressure caused by heat can cause an explosion.  Release gas ...

Countershaft gear / driveshaft gear disassembly and assembly
Refer to transmission removal  and transmission installation . Disassembly Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Drive or driven) so that they can be reinstalled in their original positions. Counte ...

Engine coolant solution
Use engine coolant that is com patible with an aluminum radiator, mixed with distilled water at a 50:50 mixture ratio for engine coolant solution. An engine coolant mixture other than 50:50 can affect cooling efficiency or rust inhibiting performance. Engine coolant Engine coolant should b ...

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