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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:

Handlebar removal and installation
Removal Remove the following parts from the left handlebar.  left handlebar switch box (1)  handlebar balancer (2)  grip rubber (3)  clutch cable (4) Remove the following parts from the right handlebar.  right handlebar switch box (5)   ...

Rear brake caliper parts inspection
Refer to rear brake caliper disassembly and assembly . Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any s ...

Special tools and equipment
Recommended service material Note required service material is also described in the following. Clutch control system components  clutch components Special tool ...

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