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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:

Drive chain cleaning and oiling
Clean and oil the chain as follows:  Wash the chain with kerosene. Kerosene will lubricate and clean the chain. Warning Kerosene can be hazardous . Kerosene is flammable. Children or pets may be harmed from contact with kerosene. Keep flames and smoking mater ...

Front wheel assembly construction
Brake disc bolt Brake caliper mounting bolt Front axle bolt Front axle pinch bolt Clearance 18 Nm (1.8 Kgf-m, 13.0 Lbf-ft) 39 Nm (3.9 Kgf-m, 28.0 Lbf-ft) 100 Nm (10 kgf-m, 72.5 Lbf-ft) 23 Nm (2.3 Kgf-m, 16.5 Lbf-ft) ...

Crankshaft thrust clearance inspection and selection
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Inspection With the crankshafts right-side and left-side thrust bearings inserted into the upper crankcase.  Measure the thrust clearance a between the leftside thrust bearing and ...

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