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:
If a collision is imminent, do something
Many riders fear locking up their
brakes or haven't learned to
swerve to avoid an accident.
Many inexperienced riders (and
too many seasoned riders) use
only their rear brake in an emergency,
resulting in unnecessary
impacts in some cases and
unnecessarily high impact speeds
in other case ...
Location of labels
Read and follow all of the warnings
labeled on your motorcycle.
Make sure you understand all of
the labels. Keep the labels on
your motorcycle. Do not remove
them for any reason.
1
Warning
Keep windshield clean at all times.
Clean only with a soh cloth and warm
...
Fuel pump components
Fuel level gauge
Fuel pressure regulator assembly
O-ring
Joint
Fuel pump
Fuel pump case
Fuel mesh filter
10
N·m (1.0 Kgf-m, 7.0 Lbf-ft)
Apply engine oil.
Apply grease.
Do not reuse.
...