Suzuki GSX-R 1000 Service Manual: Diagnostic information and procedures

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Diagnostic information and procedures

Engine mechanical symptom diagnosis

Refer to “engine symptom diagnosis” in section 1a .

Compression pressure check

The compression pressure reading of a cylinder is a good indicator of its internal condition.

The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

Note

before checking the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted.
Make sure that the battery is in fullycharged condition.

Warm up the engine.
Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
Remove the air cleaner box. Refer to “air cleaner box removal and installation” .
Remove all the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .
Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

Special tool
(a): 09915–64512 (compression
gauge)
(b): 09915–63311 (compression gauge
attachment)

Suzuki GSX-R. Compression pressure check

Keep the throttle grip in the fully-opened position.

Suzuki GSX-R. Compression pressure check

Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression.
Repeat this procedure with the other cylinders.

Compression pressure specification

Suzuki GSX-R. Compression pressure check

Low compression pressure can indicate any of the following conditions:

excessively worn cylinder walls
worn piston or piston rings
piston rings stuck in grooves
poor valve seating
ruptured or otherwise defective cylinder head gasket

Overhaul the engine in the following cases:

compression pressure in one of the cylinders is 1 000 kpa (10 kgf/cm2, 142 psi) and less.
The difference in compression pressure between any two cylinders is 200 kpa (2 kgf/cm2, 28 psi) and more.
All compression pressure readings are below 1 400 kpa (14 kgf/cm2, 199 psi) even when they measure 1 000 kpa (10 kgf/cm2, 142 psi) and more.

After checking the compression pressure, reinstall the removed parts.

Throttle cable routing diagram

Throttle cable no. 1 Throttle cable no. 2 Clutch cablev Front brake hose Pass the throttle cables in front of the front brake hose. Pass the clutch ca ...

Repair instructions

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Other materials:

Engine top side assembly
Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Cylinder head Install the dowel pins and a new cylinder head gasket (1) to the cylinder. Caution use a new gasket to prevent gas leakage. Place the cylinder head ...

Front fork removal and installation
Note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal Remove the front wheel. Refer to “front wheel assembly removal and installation” in section 2d . ...

Diagnostic information and procedures
Starting system symptom diagnosis Condition Possible cause Correction / reference item Engine does not turn though the starter motor runs Faulty starter clutch. Replace. Starter button is not effective Run down battery Repair or replac ...