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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:

Starter motor inspection
Refer to “starter motor disassembly and assembly” . Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length “a” of the carbon brushes using a v ...

Throttle body disassembly and assembly
Refer to “throttle body removal and installation” . Disassembly Caution identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. Disconnect the fuel feed hose (1), isc valve ho ...

Brake pad
Front Rear Inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1. If a pad is worn to the grooved wear limit line, it must be replaced with a new one. After replacing either the front or rear brake pads, the brake lever or pedal must be ...

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