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Suzuki GSX-R 1000 Service Manual: Valve clearance inspection and adjustment

Inspect valve clearance initially every 24 000 km (14 500 miles, 48 months)

Inspection

Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.

  1.  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
  2.  Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .
  3. Remove the cylinder head cover. Refer to “engine top side disassembly” in section 1d .
  4. Remove the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .

Valve clearance (when cold) in: 0.08 – 0.18 Mm (0.003 – 0.007 In) ex: 0.18 – 0.28 Mm (0.007 – 0.011 In)

  1. remove the valve timing inspection cap (1).

Suzuki GSX-R. Inspection


Note

  •  the cam must be at positions, “a” or “b”, when checking the valve clearance.

    Clearance readings should not be taken with the cam in any other position than these two positions.

  •  The valve clearance should be taken when each cylinder is at top dead center (tdc) of compression stroke.
  •  The clearance specification is for cold state.
  •  To turn the crankshaft for valve clearance checking, be sure to use a wrench, and rotate in the normal running direction.

Suzuki GSX-R. Inspection


  1. Turn the crankshaft to bring the line “c” on the ckp sensor rotor to the slit “d” of cap hole thread and also to bring the notches “e” on the left ends of both camshafts (ex and in) to the positions as shown.

Suzuki GSX-R. Inspection


Suzuki GSX-R. Inspection


  1. In this condition, read the valve clearance at the valves “f” (in and ex of no. 4 Cylinder, ex of no. 3 And in of no. 2). If the clearance is out of specification, adjust the clearance.

Special tool : 09900–20803 (thickness gauge)


Suzuki GSX-R. Inspection


  1. Turn the crankshaft 360° degrees (one rotation) to bring the line on the ckp sensor rotor to the rib behind the clutch cover and also to bring the notches “e” to the position as shown.

Suzuki GSX-R. Inspection


  1. Read the clearance at the rest of the valves “g” and adjust the clearance if necessary.

Suzuki GSX-R. Inspection


Suzuki GSX-R. Inspection


Adjustment

The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim.

  1.  Remove the intake or exhaust camshaft. Refer to “engine top side disassembly” in section 1d .
  2.  Remove the tappet (1) and shim (2) by fingers or magnetic hand.

Suzuki GSX-R. Adjustment


  1. Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.

Suzuki GSX-R. Adjustment


  1. Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 To 2.20 Mm in steps of 0.05 Mm.
  2.  Fit the selected shim (2) to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size.
Note

  •  be sure to apply engine oil to tappet shim top and bottom faces.
  •  When seating the tappet shim, be sure the figure printed surface faces the tappet.

Suzuki GSX-R. Adjustment


(Intake side)

Tappet shim selection table [intake] tappet shim no. (12892-05C00-xxx)

Suzuki GSX-R. Intake side


(Exhaust side)

Tappet shim selection table [exhaust] tappet shim no. (12892-05C00-xxx)

Suzuki GSX-R. Exhaust side


  1. Install the camshafts and cam chain tension adjuster.

    Refer to “engine top side assembly” in section 1d .

  2.  Rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the specified range.
  3.  After finishing the tappet clearance adjustment, reinstall the removed parts. Refer to “engine top side assembly” in section 1d .

Spark plug replacement

Replace spark plug every 12 000 km (7 500 miles, 24 months)

Refer to “ignition coil and spark plug removal and installation” in section 1h .

Exhaust control valve inspection
Inspect exhaust control valve initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Inspect exhaust control valve as follows:  remove the left ...

Spark plug inspection and cleaning
Inspect spark plug every 6 000 km (4 000 miles, 12 months) Heat range Remove the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .  Check sp ...

Other materials:

Turn signal / side-stand relay inspection
Refer to “electrical components location” in section 0a . Note make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signa ...

Inspection before riding
Warning Failure to inspect and maintain your motorcycle properly increases the chance of an accident or equipment damage. Always perform a pre-ride inspection before each ride. Refer to the table on page 4-4 for check items. For further details, refer to the inspec· ...

Front brake light switch inspection
Inspect the front brake light switch in the following procedures:  disconnect the front brake light switch coupler (1). Inspect the front brake light switch for continuity with the tester. If any abnormality is found, replace the front brake light switch with a new one. Re ...

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