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Suzuki GSX-R 1000 Service Manual: Valve guide replacement

  1. Remove the cylinder head. Refer to engine top side disassembly .
  2.  Remove the valves. Refer to cylinder head disassembly and assembly .
  3.  Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.

Special tool (a): 0991643211 (valve guide
installer & remover)

Note

  •  discard the removed valve guide subassemblies.
  •  Only oversized valve guides are available as replacement parts. (Part no. 11115- 29G70)

Suzuki GSX-R. Valve guide replacement


  1. Refinish the valve guide holes in the cylinder head using the reamer and handle.
Caution

when refinishing or removing the reamer from the valve guide hole, always turn it clockwise.

Special tool (b): 0991633320 (valve guide reamer
(9.8 Mm)) (c): 0991634542 (reamer handle)


Suzuki GSX-R. Valve guide replacement


  1. Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 150 c (212 302 f) with a hot plate.
Caution

do not use a burner to heat the valve guide hole to prevent cylinder head distortion.

  1. Apply engine oil to each valve guide and valve guide hole.
  2.  Drive the guide into the guide hole using the valve guide installer.
Caution

failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.

Special tool (a): 0991643211 (valve guide
installer & remover) (d): 0991653380 (valve guide
installer attachment)

Suzuki GSX-R. Valve guide replacement


  1. Cylinder head
  2. 13.7 13.9 Mm (0.54 0.55 In) [in and ex]

Suzuki GSX-R. Valve guide replacement


  1. After installing the valve guides, refinish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming.
Note

  •  be sure to cool down the cylinder head to ambient air temperature.
  •  Insert the reamer from the combustion chamber and always turn the reamer handle clockwise.

Special tool (c): 0991634542 (reamer handle)
(e): 0991633210 (valve guide reamer
(4.5 Mm))

Suzuki GSX-R. Valve guide replacement


  1. Reassemble the cylinder head. Refer to cylinder head disassembly and assembly .
  2.  Install the cylinder head assembly. Refer to engine top side assembly .
Cylinder head related parts inspection
Refer to cylinder head disassembly and assembly . Cylinder head distortion Decarbonize the combustion chambers.  Check the gasket surface of the cylinder head for distortion. Use a str ...

Valve seat repair
The valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45. Intake valve Exhaust valve ...

Other materials:

Stp sensor removal and installation
Removal Remove the throttle body. Refer to throttle body removal and installation in section 1d (page 1d- 10).  Remove the stp sensor (1) with the special tool. Special tool : 0993011950 (torx wrench (5 mm)) Note prior to disassembly, mark the stp sensors origina ...

DTC c31 (p0705): gp switch circuit malfunction
Detected condition and possible cause Detected condition Possible cause No gear position switch voltage Gp switch voltage is not within the following range. Gp switch voltage > 0.6 V Gp switch circuit open or short.  Gp switch malfunction. ...

Tp reset
When replacing the throttle body assembly or tp sensor with a new one or reinstalling the tp sensor, reset the tp learned value in the following procedures: Note keep the throttle valves fully closed while resetting the tp learned value. Turn the ignition switch on.   ...

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