Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: 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 camshafts removal) with the engine in place, remove the following parts:

  •  air cleaner box
  •  throttle body

Other parts except for these engine top side components can not be serviced with the engine installed in the frame. Refer to engine assembly removal  and engine assembly installation .

 

Caution

identify the position of each removed part.

Organize the parts in their respective groups (e.G., Intake, exhaust) so that they can be reinstalled in their original positions.

Cylinder head cover

  1. Remove the spark plugs. Refer to ignition coil and spark plug removal and installation in section 1h .
  2.  Remove the cylinder head cover (1) and its gasket.

Suzuki GSX-R. Cylinder head cover


  1. Remove the dowel pins and o-rings.

Suzuki GSX-R. Cylinder head cover


Camshafts

  1. Remove the valve timing inspection cap (1).

Suzuki GSX-R. Camshafts


  1. Turn the crankshaft to bring the line a on the ckp sensor rotor to the slit b of cap hole thread and also to bring the camshafts to the position as shown.

Suzuki GSX-R. Camshafts


Suzuki GSX-R. Camshafts


Suzuki GSX-R. Camshafts


  1. Remove the cam chain tension adjuster (2).

Suzuki GSX-R. Camshafts


  1. Remove the gasket (3).

Suzuki GSX-R. Camshafts


  1. Remove the cam chain guide no. 2 (4).
  2.  Remove the camshaft journal holders (5).
Caution

be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.

Suzuki GSX-R. Camshafts


  1. Remove the dowel pins.
  2. Remove the intake camshaft (6) and exhaust camshaft (7).

Suzuki GSX-R. Camshafts


Cylinder head

Note

the cylinder head can not be serviced with the engine installed in the frame.

  1. Disconnect the water bypass hose (1).

Suzuki GSX-R. Cylinder head


  1. Remove the cylinder head bolts (m6) (2).

Suzuki GSX-R. Cylinder head


  1. Remove the cylinder head bolts (m10) and washers.
Note

when loosening the cylinder head bolts, loosen each bolt little by little diagonally.

  1. Remove the cylinder head.

Suzuki GSX-R. Cylinder head


  1. Remove the dowel pins and cylinder head gasket (3).

Suzuki GSX-R. Cylinder head


Engine assembly installation
Install the engine in the reverse order of engine removal. Pay attention to the following points:  before installing the engine, install the collars (1). Before installing the en ...

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 ...

Other materials:

DTC c15 (p0115-h/l): ect sensor circuit malfunction
Detected condition and possible cause Detected condition Possible cause C15 Output voltage is not with in the following range. 0.15 V ≤ Sensor voltage < 4.85 V Ect sensor circuit open or short.  Ect sensor malfunction.  Ec ...

Fuel level gauge inspection
Inspect the fuel level gauge in the following procedures:  remove the fuel pump. Refer to fuel pump disassembly and assembly in section 1g .  Measure the resistance at each fuel level gauge in float position. If the resistance is incorrect, replace fuel level gauge with a ne ...

Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the national highway traffic safety administration (nhtsa) in addition to notifying american suzuki motor corp. If nhtsa receives similar complaints, it ma ...

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