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

Removal

  1. Remove the piston. Refer to engine bottom side disassembly .
  2.  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


  1. 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.
  1. Install the piston rings in the order of the oil ring, second ring and top ring.
  2. 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


  1. Incorrect
  2. Correct
  1. 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


  1. 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


  1. 1St ring and upper side rail
  2. Spacer
  3. 2Nd ring and lower side rail
  4. In
  5. Ex
  1. 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:

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Inspect the clutch lever position switch in the following procedures:  disconnect the clutch lever position switch lead wires (1). Inspect the clutch lever position switch for continuity with the tester. If any abnormality is found, replace the switch with a new one. S ...

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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 .  Remove the washers, balancer gear and dampers from the shaft. Assembly Assembly is in the re ...

DTC c40 (p0505 / p0506 / p0507): isc valve circuit malfunction
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