Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Engine bottom side disassembly

Note

the crankcase must be separated to service the crankshaft and conrod.

  1. Remove the engine assembly from the frame. Refer to “engine assembly removal” .
  2.  Remove the engine top side (1). Refer to “engine top side disassembly” .

Crankcase breather (pcv) cover

Remove the crankcase breather (pcv) cover (1).

Suzuki GSX-R. Crankcase breather (pcv) cover


Starter motor

Remove the starter motor (1).

Suzuki GSX-R. Starter motor


Clutch

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

Suzuki GSX-R. Clutch


Gearshift system

Remove the gearshift shaft (1) and gearshift cam plate (2). Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .

Suzuki GSX-R. Gearshift system


Starter torque limiter / starter clutch

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

Suzuki GSX-R. Starter torque limiter / starter clutch


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

  1. Remove the washer (1).

Suzuki GSX-R. Cam chain / cam chain tensioner / cam chain guide


  1. Remove the cam chain tensioner (2) and cam chain guide no. 1 (3).
  2.  Remove the cam chain drive sprocket (4) and cam chain (5).

Suzuki GSX-R. Cam chain / cam chain tensioner / cam chain guide


Generator

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

Suzuki GSX-R. Generator


Water pump

  1. Remove the water inlet connector (1).

Suzuki GSX-R. Water pump


  1. Remove the water pump (2).

Suzuki GSX-R. Water pump


Gear position switch

Remove the gear position switch (1).

Suzuki GSX-R. Gear position switch


Oil pressure switch

Remove the oil pressure switch lead wire (1) and switch (2).

Suzuki GSX-R. Oil pressure switch


Oil filter

Remove the oil filter (1) with the special tool.

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


Suzuki GSX-R. Oil filte


Oil pan

  1. Remove the plate (1).
  2.  Remove the oil pan (2) and gasket.

Suzuki GSX-R. Oil pan


Oil pressure regulator / oil strainer

  1. Remove the oil pressure regulator (1).
  2.  Remove the oil strainer (2).

Suzuki GSX-R. Oil pressure regulator / oil strainer


  1. Remove the o-ring (3).

Suzuki GSX-R. Oil pressure regulator / oil strainer


Oil pump

  1. Remove the spacer (1) and bearing (2).

Suzuki GSX-R. Oil pump


  1. Remove the oil pump drive sprocket (3) and chain (4).
  2.  Remove the thrust washer (5).

Suzuki GSX-R. Oil pump


  1. Remove the oil pump assembly (6).
  2.  Remove the dowel pins and o-ring (7).

Suzuki GSX-R. Oil pump


  1. Remove the breather oil return pipe (8).

Suzuki GSX-R. Oil pump


Crankcase

  1. Remove the clutch push rod oil seal retainer (1).

Suzuki GSX-R. Crankcase


  1. Remove the cap (2).
  2.  Remove the crankcase bolts from upper side.
Note

loosen the crankcase bolts diagonally and smaller size ones first.

Suzuki GSX-R. Crankcase


Suzuki GSX-R. Crankcase


  1. Remove the crankcase bolts from lower side.
  2. Remove the crankshaft journal bolts (m9).

Suzuki GSX-R. Crankcase


  1. Make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic hammer to separate the upper and lower crankcase halves and then lift the lower crankcase off the upper crankcase.
  2.  Remove the dowel pins and o-rings (3).

Suzuki GSX-R. Crankcase


Balancer shaft

Remove the balancer shaft assembly (1) and plug (2).

Suzuki GSX-R. Balancer shaft


Transmission

Remove the transmission component. Refer to “transmission removal” in section 5b .

Suzuki GSX-R. Transmission


Suzuki GSX-R. Transmission


Crankshaft

  1. Loosen the conrod cap bolts using a 10 mm, 12- point socket wrench.

Suzuki GSX-R. Crankshaft


  1. Remove the conrod caps by tapping the bolts lightly with a plastic hammer.

Suzuki GSX-R. Crankshaft


  1. Remove the crankshaft (1) and thrust bearings (2).

Suzuki GSX-R. Crankshaft


Piston cooling oil jet

Remove the piston cooling oil jet (1) from the upper crankcase.

Suzuki GSX-R. Piston cooling oil jet


Piston / conrod

  1. Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.
Caution

be careful not to damage the cylinder wall by the conrod.

Suzuki GSX-R. Piston / conrod


Suzuki GSX-R. Piston / conrod


  1. Remove the piston pin circlip (1).

Suzuki GSX-R. Piston / conrod


  1. Draw out the piston pin (2) and remove the piston from the conrod.
Note

scribe the cylinder number on the piston head.

Suzuki GSX-R. Piston / conrod


Crankshaft journal bearing

Remove the crankshaft journal bearings, upper and lower.

Caution

  •  when removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.
  •  Do not touch the bearing surfaces with your hands. Grasp the bearings by their edges.

 

Note

  •  do not remove the crankshaft journal bearings unless absolutely necessary.
  •  Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.

Suzuki GSX-R. Crankshaft journal bearing


Suzuki GSX-R. Crankshaft journal bearing


Oil jet

Remove the oil jet (1) (for transmission) from the lower crankcase.

Suzuki GSX-R. Oil jet


Oil gallery plug

  1. Remove the oil gallery plug (1), (2) and (3) from the lower crankcase.

Suzuki GSX-R. Oil gallery plug


Suzuki GSX-R. Oil gallery plug


Suzuki GSX-R. Oil gallery plug


  1. Remove the oil gallery plug (4) from the upper crankcase.

Suzuki GSX-R. Oil gallery plug


Water jacket plug

Remove the water jacket plugs (1) from the upper crankcase.

Suzuki GSX-R. Water jacket plug


Oil seal / bearing

Remove the oil seal and bearings if necessary. Refer to “transmission removal” in section 5b .

Suzuki GSX-R. Oil seal / bearing


Breather oil return plate

Remove the breather oil return plate (1) from the upper crankcase.

Suzuki GSX-R. Breather oil return plate


Valve seat repair
The valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45°. Intake valve Exhaust valve ...

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. ...

Other materials:

Iat sensor removal and installation
Removal Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Remove the iat sensor (1) from the air cleaner box. Installation Install the iat sensor in the reverse order of removal. Pay attention to the following point:  t ...

Valve clearance inspection and adjustment
Inspect valve clearance initially every 24 000 km (14 500 miles, 48 months) Inspection Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.  Lift an ...

Drive chain replacement
Use the special tool in the following procedures, to cut and rejoin the drive chain. Note when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Special tool : 09922–22711 (drive chain cutting and joint tool set) Driv ...

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