Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: 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.

Breather oil return plate

When installing the breather oil return plate (1), apply thread lock to the bolts.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Suzuki GSX-R. Breather oil return plate


Oil seal / bearing

Install the oil seal and bearings. Refer to “transmission installation” in section 5b .

Water jacket plug

Caution

replace the o-rings with new ones.

Tightening torque water jacket plug (a): 9.5 N·m (0.95 Kgf-m, 6.9 Lbfft)

Suzuki GSX-R. Water jacket plug


Oil gallery plug

Caution

replace the gaskets with new ones.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque oil gallery plug (m10) (a): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft)

Suzuki GSX-R. Water jacket plug


: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque oil gallery plug (m12) (b): 15 n·m (1.5 Kgf-m, 11.0 Lbf-ft)

Suzuki GSX-R. Water jacket plug


Tightening torque oil gallery plug (m26) (c): 11 n·m (1.1 Kgf-m, 8.0 Lbf-ft) oil gallery plug (m6) (d): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Water jacket plug


Suzuki GSX-R. Water jacket plug


Oil jet

Install the oil jet (1) (for transmission).

Suzuki GSX-R. Oil jet


Crankshaft journal bearing

When fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix the stopper part “a” first and press the other end.

Caution

do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.

 

Note

inspect and select the crankshaft journal bearing if necessary. Refer to “crankshaft journal bearing inspection and selection” .

Suzuki GSX-R. Crankshaft journal bearing


Piston and conrod

M/o: molybdenum oil (molybdenum oil solution)

Note

when installing the pistons, the indent “a” on the piston head must be brought to the other side of id code “b” on the conrod big end.

Suzuki GSX-R. Piston and conrod


Caution

use new piston pin circlips (1) to prevent circlip failure which will occur when it is bent.

 

Note

end gap of the circlip “c” should not be aligned with the cutaway in the piston pin bore.

Suzuki GSX-R. Piston and conrod


M/o: molybdenum oil (molybdenum oil solution)

Note

be sure to install the pistons in the cylinders from which they were removed in disassembly, referring to the cylinder numbers, #1 through #4, scribed on the piston.

Suzuki GSX-R. Piston and conrod


Note

when installing the pistons, the indent “d” of each piston head must be brought to the exhaust side.

Special tool (a): 09916–77310 (piston ring
compressor)

Suzuki GSX-R. Piston and conrod


Caution

be sure to clean the conrod big end.

Suzuki GSX-R. Piston and conrod


Piston cooling oil jet

Caution

use new o-ring to prevent oil pressure leakage.

Suzuki GSX-R. Piston cooling oil jet


Note

apply a small quantity of thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque piston cooling oil jet bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Piston cooling oil jet


Crankshaft

  1. Apply molybdenum oil to each crank pin bearing surface and crankshaft journal bearing surface.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Crankshaft


  1. Position the no. 2 And no. 3 Conrod big ends on the same side, and the no. 1 And no. 4 Conrod big ends on the opposite side of no. 2 And no. 3.

Suzuki GSX-R. Crankshaft


  1. Set the crankshaft onto the conrods and upper crankcase.

Suzuki GSX-R. Crankshaft


  1. Apply molybdenum oil to each crank pin and bearing surface.
Caution

be sure to clean the conrod big end.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Crankshaft


  1. When fitting the conrod cap, make sure that I.D.

    Code “a” on each conrod faces intake side.

  2. Apply engine oil to the conrod cap bolts.

Suzuki GSX-R. Crankshaft


  1. Tighten the conrod cap bolt by using a 10 mm, 12 point socket wrench in the following two steps.

Tightening torque conrod cap bolt: 37 n·m (3.7 Kgf-m, 26.5 Lbf-ft) then turn in 1/6 (60°) turn

Suzuki GSX-R. Crankshaft


Suzuki GSX-R. Crankshaft


  1. 60°
  1. Apply engine oil to the conrod big end side surfaces.
  2.  Apply molybdenum oil to each crankshaft journal and bearing lightly.

M/o: molybdenum oil (molybdenum oil solution)

  1. Check the conrod movement for smooth turning.

Suzuki GSX-R. Crankshaft


  1. Insert the right and left thrust bearings with the oil grooves “b” facing towards the crankshaft web.
Note

  •  right-thrust bearing has green painting.
  •  Inspect and select the crankshaft thrust clearance if necessary. Refer to “crankshaft thrust clearance inspection and selection” .

Suzuki GSX-R. Crankshaft


Transmission

Install the transmission. Refer to “transmission installation” in section 5b .

Suzuki GSX-R. Transmission


Suzuki GSX-R. Transmission


Balancer shaft

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Balancer shaft


Suzuki GSX-R. Balancer shaft


Crankcase

Caution

replace the o-rings with new ones.

Suzuki GSX-R. Crankcase


Note

  •  make mating surfaces free from moisture, oil, dust and other foreign materials.
  •  Spread the sealant on surfaces thinly to form an even layer, and assemble the crankcases within a few minutes.
  •  Take extreme care not to apply sealant to any oil hole, oil groove and bearing.
  •  Apply sealant to distorted surfaces as it forms a comparatively thick film.

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

Suzuki GSX-R. Crankcase


Caution

fit new gasket washers to the bolts “a” to prevent oil leakage.

Tightening torque crankshaft journal bolt (m9): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft) then turn in 50°

Suzuki GSX-R. Crankcase


Caution

  •  fit new gasket washers to the bolts “b” to prevent oil leakage.
  •  Fit new o-ring to the cap (2) and apply grease to it.

Tightening torque crankcase bolt (m8) (initial): 15 n·m (1.5 Kgf-m, 11.0 Lbf-ft) crankcase bolt (m8) (final): 26 n·m (2.6 Kgf-m, 19.0 Lbf-ft) crankcase bolt (m6): 12 n·m (1.2 Kgf-m, 8.5 Lbf-ft)

Suzuki GSX-R. Crankcase


Suzuki GSX-R. Crankcase


Suzuki GSX-R. Crankcase


Suzuki GSX-R. Crankcase


Suzuki GSX-R. Crankcase


: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Suzuki GSX-R. Crankcase


Oil pump

Suzuki GSX-R. Oil pump


: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Caution

use a new o-ring to prevent oil leakage.

Suzuki GSX-R. Oil pump


Tightening torque oil pump mounting bolt: 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Oil pump


Note

the chamfer side “a” of thrust washer should face the crankcase side.

Suzuki GSX-R. Oil pump


Note

teeth “b” on the sprocket must face the clutch side.

Suzuki GSX-R. Oil pump


Suzuki GSX-R. Oil pump


Oil strainer / oil pressure regulator

Caution

use a new o-ring to prevent oil leakage.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Oil strainer / oil pressure regulator


Caution

use a new o-ring to prevent oil leakage.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Oil strainer / oil pressure regulator


Oil pan

Caution

use new gasket to prevent oil leakage.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque oil pan bolt: 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Oil pan


Oil filter

Install the oil filter with the special tool. Refer to “engine oil and filter replacement” in section 0b .

Special tool (a): 09915–40610 (oil filter wrench)


Suzuki GSX-R. Oil pan


Oil pressure switch

Note

be careful not to apply bond to the hole of thread end.

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

Tightening torque oil pressure switch: 14 n·m (1.4 Kgf-m, 10.0 Lbf-ft)

Suzuki GSX-R. Oil pressure switch


Gear position switch

Caution

replace the o-ring with a new one.

 

Note

insert the gear position switch pin “a” into the gearshift cam hole “b”.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Gear position switch


Tightening torque gear position switch mounting bolt (a): 6.5 N·m ( 0.65 Kgf-m, 4.7 Lbf-ft)

Suzuki GSX-R. Gear position switch


Water pump

Caution

use the new o-ring to prevent oil leakage.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Water pump


Tightening torque water pump mounting bolt (a): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)

Suzuki GSX-R. Water pump


Caution

replace the o-ring with a new one.

Suzuki GSX-R. Water pump


Generator

Install the generator rotor and cover (1). Refer to “generator removal and installation” in section 1j .

Suzuki GSX-R. Generator


Cam chain / cam chain tensioner / cam chain guide no. 1

Note

when installing the cam chain drive sprocket, align the wide spline teeth of the sprocket and crankshaft.

Suzuki GSX-R. Generator


Tightening torque cam chain tensioner bolt (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

Tightening torque cam chain guide no. 1 Bolt (b): 23 n·m (2.3 Kgfm, 16.5 Lbf-ft)

Suzuki GSX-R. Generator


Suzuki GSX-R. Generator


Starter clutch / starter torque limiter

Install the starter clutch (1) and starter torque limiter (2) component parts. Refer to “starter clutch removal and installation” in section 1i  and “starter torque limiter removal and installation” in section 1i .

Suzuki GSX-R. Starter clutch / starter torque limiter


Gearshift system

Install the gearshift cam plate (1) and gearshift shaft (2).

Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .

Suzuki GSX-R. Gearshift system


Clutch

Install the clutch component parts (1). Refer to “clutch installation” in section 5c .

Suzuki GSX-R. Clutch


Starter motor

Install the starter motor (1). Refer to “starter motor removal and installation” in section 1i .

Suzuki GSX-R. Starter motor


Crankcase breather (pcv) cover

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

Suzuki GSX-R. Crankcase breather (pcv) cover


Suzuki GSX-R. Crankcase breather (pcv) cover


Engine top side

Assemble the engine top side. Refer to “engine top side disassembly” .

Engine bottom side disassembly
Note the crankcase must be separated to service the crankshaft and conrod. Remove the engine assembly from the frame. Refer to “engine assembly removal” .  Remove the e ...

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 gau ...

Other materials:

Open circuit check
Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.  Loose connection of connector/coupler.  Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of f ...

Sprocket mounting drum dust seal / bearing removal and installation
Removal Remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation” in section 2d .  Remove the rear sprocket mounting drum assembly (1). Refer to “rear sprocket / rear sprocket mounting drum removal and installation” (page 3a- 3). Remove the ...

Iat sensor inspection
Refer to “dtc “c21” (p0110-h/l): iat sensor circuit malfunction” in section 1a . Inspect the iat sensor. Note iat sensor resistance measurement method is the same way as that of the ect sensor. Refer to “ect sensor inspection” (page 1c- 4).   Caution & ...

© 2011-2017 Copyright www.suzukigsxr.org