Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Piston and piston ring inspection

Refer to piston ring removal and installation .

Piston diameter

Measure the piston diameter using the micrometer at 15 mm (0.6 In) a from the skirt end. If the piston diameter is less than the service limit, replace the piston.

Special tool (a): 0990020203 (micrometer (50
75 mm))

Piston diameter service limit: 74.380 Mm (2.9283 In)

Suzuki GSX-R. Piston diameter


Suzuki GSX-R. Piston diameter


Piston-to-cylinder clearance

Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.

Piston-to-cylinder clearance service limit: 0.120 Mm (0.0047 In)

Piston ring-to-groove clearance

Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings.

Special tool (a): 0990020803 (thickness gauge)
(b): 0990020205 (micrometer (0 25
mm))

Piston ring-to-groove clearance service limit (1st): 0.180 Mm (0.0071 In) service limit (2nd): 0.150 Mm (0.0059 In)

Piston ring groove width standard (1st): 0.83 0.85 Mm (0.0327 0.0335 In) standard (1st): 1.30 1.32 Mm (0.0512 0.0520 In) standard (2nd): 0.81 0.83 Mm (0.0319 0.0327 In) standard (oil): 1.51 1.53 Mm (0.0594 0.0602 In)

Piston ring thickness standard (1st): 0.76 0.81 Mm (0.0299 0.0319 In) standard (1st): 1.08 1.10 Mm (0.0425 0.0433 In) standard (2nd): 0.77 0.79 Mm (0.0303 0.0311 In)

Suzuki GSX-R. Piston diameter


Suzuki GSX-R. Piston diameter


Piston ring free end gap and piston ring end gap

Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service limit, replace the piston ring with a new one.

Special tool (a): 0990020102 (vernier calipers
(200 mm))

Piston ring free end gap service limit (1st): 5.6 Mm (0.22 In) service limit (2nd): 6.4 Mm (0.25 In)

Special tool (b): 0990020803 (thickness gauge)


Piston ring end gap service limit (1st): 0.50 Mm (0.020 In) service limit (2nd): 0.50 Mm (0.020 In)

Suzuki GSX-R. Piston ring free end gap and piston ring end gap


Suzuki GSX-R. Piston ring free end gap and piston ring end gap


Piston pin and pin bore

Measure the piston pin bore inside diameter using the small bore gauge. If either is out of specification or the difference between these measurements surpass limits, replace the piston.

Special tool (a): 0990020602 (dial gauge)
(b): 0990022401 (small bore gauge
(10 18 mm))

Piston pin bore service limit: 15.030 Mm (0.5917 In)

Suzuki GSX-R. Piston pin and pin bore


Measure the piston pin outside diameter at three positions using the micrometer. If any of the measurements are out of specification, replace the piston pin.

Special tool (c): 0990020205 (micrometer (0 25
mm))

Piston pin o.D.

Service limit: 14.980 Mm (0.5898 In)

Suzuki GSX-R. Piston pin and pin bore


Piston ring removal and installation
Removal Remove the piston. Refer to engine bottom side disassembly .  Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove i ...

Balancer shaft disassembly and assembly
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Disassembly Remove the balancer shaft. Refer to engine bottom side disassembly .  Re ...

Other materials:

Transmission components
2Nd drive gear 6Th drive gear 3Rd/4th drive gear 5Th drive gear Countershaft/1st drive gear Driveshaft 2Nd driven gear 6Th driven gear 3Rd driven gear 4Th driven gear 5Th driven gear 1St driven gear Gearshift cam stopper Gearshi ...

Drive chain
This motorcycle has a master link type drive chain. We recommend that you take your motorcycle to an authorized suzuki dealer if the drive chain needs replacing. The condition and adjustment of the drive chain should be checked each day before you ride. Always follow the guidelines for ins ...

Swingarm related parts inspection
Refer to swingarm removal and installation (page 2c- 9). Spacers Remove the collar and spacer from the swingarm.  Inspect the collars and spacer for wear and damage. If any defects are found, replace them with new ones. Chain buffer Inspect the chain buffer for wear and ...

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