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:
Fuel tank removal and installation
Removal
Keep away from fire or spark.
Spilled gasoline should be wiped off
immediately.
Work in a well-ventilated area.
Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Take ...
Tire removal and installation
Removal
The most critical factor of a tubeless tire is the seal
between the wheel rim and the tire bead. For this
reason, it is recommended to use a tire changer that can
satisfy this sealing requirement and can make the
operation efficient as well as functional.
Removal the wheel ass ...
Crankcase breather (pcv) hose / reed
valve / cover removal and installation
Removal
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the crankcase breather (pcv) hose (1).
...