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Suzuki GSX-R 1000 Service Manual: Engine top side assembly

Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points:

Cylinder head

Caution

use a new gasket to prevent gas leakage.

Suzuki GSX-R. Cylinder head


Note

  •  when installing the cylinder head, keep the cam chain taut.
  •  Apply engine oil to the washer and thread portion of the cylinder head bolts (m10) before tightening them.

Suzuki GSX-R. Cylinder head


Tightening torque cylinder head bolt (m10): 31 nm (3.1 Kgf-m, 22.5 Lbf-ft) then turn in 1/6 (60) turn

Suzuki GSX-R. Cylinder head


Tightening torque cylinder head bolt (m6) (a): 10 nm (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Cylinder head


Suzuki GSX-R. Cylinder head


Camshaft

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Camshaft


Caution

  •  pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket.
  •  To adjust the camshaft timing correctly, be sure to align the line a with slit b and hold this position when installing the camshafts.

Suzuki GSX-R. Camshaft


Suzuki GSX-R. Camshaft


Note

before installing the camshaft, check that the tappets are installed correctly.

Note

the cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster are secured.

Suzuki GSX-R. Camshaft


Suzuki GSX-R. Camshaft


Suzuki GSX-R. Camshaft


Suzuki GSX-R. Camshaft


Note

  •  damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
  •  Each camshaft journal holder is identified with a cast-on letter f.
  •  The ascending order of numbers are indicated on the camshaft journal holders.

Suzuki GSX-R. Camshaft


Tightening torque camshaft journal holder bolt: 10 nm (1.0 Kgf-m, 7.0 Lbf-ft)

Caution

the camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts.

Take special care not to use other types of bolts.

Suzuki GSX-R. v


Suzuki GSX-R. Camshaft


Cam chain tension adjuster

Caution

do not turn the adjuster body until the outer circlip a exceeds the groove b.

If the inner circlip c is caught in the groove b, plunger may not go out automatically from the adjuster body even if pushing force is applied on the head.

In such case, it needs to be disassembled.

Suzuki GSX-R. Cam chain tension adjuster


Suzuki GSX-R. Cam chain tension adjuster


Suzuki GSX-R. Cam chain tension adjuster


Caution

use a new gasket to prevent oil leakage.

Suzuki GSX-R. Cam chain tension adjuster


Tightening torque cam chain tension adjuster mounting bolt (a): 10 nm (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Cam chain tension adjuster


Caution

make sure that the adjuster works properly by checking no slack at point d.

Suzuki GSX-R. Cam chain tension adjuster


Suzuki GSX-R. Cam chain tension adjuster


Suzuki GSX-R. Cam chain tension adjuster


Note

the cam chain tension adjuster can be serviced with the engine installed in the frame.

Caution

use a new gasket to prevent oil leakage.

Tightening torque cam chain tension adjuster service cap (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Caution

use a new o-ring to prevent oil leakage.

Tightening torque valve timing inspection cap (c): 11 nm (1.1 Kgfm, 8.0 Lbf-ft)

Suzuki GSX-R. Cam chain tension adjuster


Cylinder head cover

Caution

replace the o-rings with new ones.

Suzuki GSX-R. Cylinder head cover


: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

Caution

use new gaskets to prevent oil leakage.

Suzuki GSX-R. Cylinder head cover


Caution

use new gaskets to prevent oil leakage.

Suzuki GSX-R. Cylinder head cover


Tightening torque cylinder head cover bolt (initial): 10 nm (1.0 Kgfm, 7.0 Lbf-ft) cylinder head cover bolt (final): 14 nm (1.4 Kgfm, 10.0 Lbf-ft)

Suzuki GSX-R. Cylinder head cover


Engine top side disassembly
It is unnecessary to remove the engine assembly from the frame when servicing the cylinder head cover and camshafts. Note before servicing the engine top side components (until camshaf ...

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