Suzuki GSX-R 1000 Service Manual: Valve guide replacement

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Valve guide replacement

Remove the cylinder head. Refer to “engine top side disassembly” .
Remove the valves. Refer to “cylinder head disassembly and assembly” .
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

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

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.

Apply engine oil to each valve guide and valve guide hole.
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

Cylinder head
13.7 – 13.9 Mm (0.54 – 0.55 In) [in and ex]

Suzuki GSX-R. Valve guide replacement

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

Reassemble the cylinder head. Refer to “cylinder head disassembly and assembly” .
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:

Balancer shaft disassembly and assembly
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Disassembly Remove the balancer shaft. Refer to “engine bottom side disassembly” . Remove the washers, balancer gear and dampers from the shaft. Assembly Assembly is in the re ...

Dimmer / passing light switch inspection
Inspect the dimmer/passing light 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 dimmer/passing light switch ...

Gearshift linkage inspection
Refer to “gearshift shaft / gearshift cam plate removal and installation” . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...