Suzuki GSX-R 1000 Service Manual: 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. |
- Remove the 2nd ring and oil ring in the same manner.
Installation
Note
|
- 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).
| Caution when installing the spacer, be careful not to allow its two ends to overlap in the groove. |
|
- Install the 2nd ring (3) and 1st ring (4) to piston.
| Note 1st ring (4) and 2nd ring (3) differ in shape. |
| Note face the side with the stamped mark upward when assembling. |
- 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.
|
- 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:
Hazard switch inspection
Inspect the hazard switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the left handlebar switch coupler (1).
(Yellow)
Inspect the hazard switch for continuity with the
tes ...
Specifications
Service data
Brake
unit: mm (in)
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Front brake hose routing diagram” “rear brake hose routing
diagram” “front brake master cylinder components” “rear
...
Storage procedure
If your motorcycle is to be left
unused for an extended period of
time, it needs special servicing
requiring appropriate materials,
equipment and skill. For this reason,
suzuki recommends that you
trust this maintenance work to
your suzuki dealer. If you wish to
service the machine for stora ...