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Suzuki GSX-R 1000 Service Manual: 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:

Specifications
Service data Drive train unit: mm (in) except ratio Tightening torque specifications Note the specified tightening torque is described in the following. “Transmission components”  “gearshift lever construction”  “gearshift shaft / gearshift cam plate componen ...

Clamp
Clamp the wire harness at such positions as indicated in “wiring harness routing diagram” in section 9a .  Bend the clamp properly so that the wire harness is clamped securely.  In clamping the wire harness, use care not to allow it to hang down.  Do not use wire or an ...

Gear position (gp) switch removal and installation
Removal Turn the ignition switch off.  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).  Disconnect the gear position switch lead wire coupler (1). Remove the engine sprocket cover. Refer to “engine sprocket r ...

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