Suzuki GSX-R 1000 Service Manual: 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
|
- 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)
- 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)
|
- After installing the valve guides, refinish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming.
Note
|
Special tool
(c): 09916–34542 (reamer handle)
(e): 09916–33210 (valve guide reamer
(4.5
Mm))
- 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:
Crankcase emission control system
description
The engine is equipped with a pcv system to prevent discharging crankcase
emissions into the atmosphere. Blow-by
gas in the engine is constantly drawn into the crankcase, which is returned to
the combustion chamber through the
pcv (breather) hose, air cleaner and throttle body.
...
Steering / steering damper removal and
installation
Removal
steering damper
Turn the ignition switch off.
Disconnect the steering damper solenoid coupler
(1).
Remove the lower bracket cover (2).
Remove the steering damper mounting nut (3) while
holding the lock-nut (4).
Remove the steering damper mounting bolt ( ...
Crankcase breather (pcv) hose inspection
Inspect the crankcase breather (pcv) hose in the
following procedures:
lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Inspect the crankcase breather (pcv) hose (1) for
wear and damage.
If it is worn or damaged ...