Suzuki GSX-R 1000 Service Manual: Piston ring removal and installation

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / 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 it.

Note

do not expand the piston ring excessively since it is apt to be broken down.

Suzuki GSX-R. Removal

Remove the 2nd ring and oil ring in the same manner.

Installation

Note

when installing the piston ring, be careful not to damage the piston.
Do not expand the piston ring excessively since it is apt to be broken down.

Install the piston rings in the order of the oil ring, second ring and top ring.
the first member to go into the oil ring groove is the spacer (1).
After placing the spacer, fit the two side rails (2).

Suzuki GSX-R. Installation

Caution

when installing the spacer, be careful not to allow its two ends to overlap in the groove.

Suzuki GSX-R. Installation

Incorrect
Correct

Install the 2nd ring (3) and 1st ring (4) to piston.

Note

1st ring (4) and 2nd ring (3) differ in shape.

Suzuki GSX-R. Installation

Note

face the side with the stamped mark upward when assembling.

Suzuki GSX-R. Installation

Position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, check that the gaps are so located.

Suzuki GSX-R. Installation

1St ring and upper side rail
Spacer
2Nd ring and lower side rail
In
Ex

Install each piston and piston pin. Refer to “engine bottom side assembly” .

Cylinder inspection

Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Cylinder distortion Check the gasket surface of the cylinder for distortion. Use a straightedge and thickness gau ...

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 ...

Other materials:

Specifications
Service data Suspension unit: mm (in) Tightening torque specifications Note the specified tightening torque is described in the following. “Rear suspension components” “rear suspension assembly construction” Reference: for the tightening torque of fastener ...

Combination meter inspection
Led inspection Check that the leds “a” (fi, fuel, engine rpm, oil pressure/engine coolant, immobilizer (e-02, 19, 24, 51) and meter panel illumination) immediately light up when the ignition switch is turned on. Check that the other leds “b” (neutral, high-beam and turn signal indicator ligh ...

Steering components
Steering stem head nut Steering stem upper bracket Steering stem lock-nut Washer Steering stem nut Dust seal cover Dust seal Steering stem upper bearing Steering stem lower bearing Lower seal Steering stem lower bracket Steering stem lo ...