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:

Air cleaner
The air cleaner element must be kept clean to provide good engine power and g1as mileage. If you use your motorcycle under normal low-stress conditions, you should service the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the ...

Body frame construction
Frame Seat rail Seat rail bolt Collar Engine mounting thrust adjuster Engine mounting thrust adjuster lock-nut Engine mounting pinch bolt 50 Nm (5.0 Kgf-m, 36.0 Lbf-ft) 23 Nm (2.3 Kgf-m, 16.5 Lbf-ft) 45 Nm (4.5 Kgf-m, 32. ...

Clutch cable removal and installation
Removal Remove the left side cowling. Refer to exterior parts removal and installation in section 9d .  Disconnect the clutch cable from the clutch lever. Refer to handlebar removal and installation in section 6b .  Remove the clutch cable as shown in the throttle cable ro ...

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