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)
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)
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:
Starter torque limiter inspection
Removal
Remove the clutch cover. Refer to “clutch removal” in section 5c .
Remove the washers (1), starter idle gear no. 1 (2)
And no. 2 (3).
Remove the starter idle gear no. 2 Bearing (4), shaft
(5) and washer (6).
Hold the starter clutch with the special tool an ...
Clutch removal
Drain engine oil. Refer to “engine oil and filter replacement” in
section 0b .
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Disconnect the ckp sensor coupler (1).
Remove the clutch cover (2).
...
Specifications
Service data
Fi sensors
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Exhaust control system construction” “exhaust system components”
Reference: for the tightening torque of fastener not specified in this ...