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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:

Rear brake hose removal and installation
Removal Drain brake fluid. Refer to “brake fluid replacement” .  Remove the rear brake hoses as shown in the rear brake hose routing diagram. Refer to “rear brake hose routing diagram” . Installation Caution the seal washers should be replaced with new ones to prevent ...

Excva pulley inspection
Inspect the excva pulley in the following procedures:  remove the excva pulley. Refer to “excv cable removal and installation” .  Visually inspect the excva pulley for wear and damage. If there is anything unusual, replace the pulley with a new one. Install the pulle ...

DTC “c23” (p1651-h/l): to sensor circuit malfunction
Detected condition and possible cause Detected condition Possible cause C23 The sensor voltage should be the following for 2 sec. And more, after ignition switch is turned on. 0.2 V ≤ Sensor voltage < 4.8 V To sensor circuit open or shor ...

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