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Suzuki GSX-R 1000 Service Manual: Valve guide replacement

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / 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): 09916–43211 (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): 09916–33320 (valve guide reamer
(9.8 Mm)) (c): 09916–34542 (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): 09916–43211 (valve guide
installer & remover) (d): 09916–53380 (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): 09916–34542 (reamer handle)
(e): 09916–33210 (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:

Air cleaner box removal and installation
Removal Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Remove the air cleaner box cover. Refer to “air cleaner element removal and installation” .  Remove the air cleaner mounting bolt. Remove the air clea ...

Fuel pump components
Fuel level gauge Fuel pressure regulator assembly O-ring Joint Fuel pump Fuel pump case Fuel mesh filter 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) Apply engine oil. Apply grease. Do not reuse. ...

Cam chain guide / cam chain tensioner removal and installation
Removal Remove the cylinder head cover. Refer to “engine top side disassembly” .  Remove the cam chain guide no. 2 (1). Remove the cylinder head. Refer to “engine top side disassembly”  and “engine bottom side disassembly” .  Remove the starter clutch. Refer to “s ...

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