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Suzuki GSX-R 1000 Service Manual: Cylinder head cover disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Cylinder head cover disassembly and assembly

Disassembly

  1. Remove the cylinder head cover. Refer to “engine top side disassembly” .
  2.  Remove the gaskets (1) and (2).

Suzuki GSX-R. Disassembly


  1. Remove the pair control solenoid valve (3) along with the pair reed valve covers (4).

Suzuki GSX-R. Disassembly


  1. Remove the pair reed valves (5) and cmp sensor (6).

Suzuki GSX-R. Disassembly


Assembly

Assembly is in the reverse order of disassembly. Pay attention to the following points:

Note

when installing the cmp sensor, clean the sensor surface.

Tightening torque cmp sensor bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Assembly


: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque pair reed valve cover bolt (b): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Assembly


Engine top side assembly
Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: Cylinder head Install the dowel pins and a new cylinder head gasket (1) to the cylinder ...

Cylinder head cover related parts inspection
Refer to “engine top side disassembly” . Refer to “engine top side assembly” . Refer to “cylinder head cover disassembly and assembly” . Cylinder head cover Clean and check the gasket grooves ...

Other materials:

Swingarm bearing removal and installation
Removal Remove the swingarm. Refer to “swingarm removal and installation” .  Remove the swingarm pivot bearings (1) using the special tool. Special tool (a): 09921–20240 (bearing remover set) Remove the center spacer (2). Remove the cushion lever bearing (3) usin ...

Brake fluid
Check the brake fluid level in both front and rear brake fluid reservoirs. If the level in either reservoir is below the lower mark, inspect for brake pad wear and leaks. Warning Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or ...

Know your limits
Always ride within the boundaries of your own skills. Knowing these limits and staying within them will help you avoid accidents. A major cause of accidents involving only a motorcycle (and no cars) is going too fast through a turn. Before entering a turn, select an appropriately low corne ...

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