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

Refer to “engine top side disassembly” .

Refer to “engine top side assembly” .

Disassembly

1. Remove the tappet (1) and shim (2) by fingers or magnetic hand.

2. Insert the special tool (a) between the valve springs and cylinder head.
3.  Using the special tools, compress the valve springs and remove the two cotter halves (3) from the valve stem.

Special tool (a): 09919–28620 (sleeve protector)
(b): 09916–14522 (valve lifter
attachment) (c): 09916–14510 (valve lifter)
: 09916–84511 (tweezer)

4. Remove the valve spring retainer (4) and valve springs (5).
5. Pull out the valve (6) from the combustion chamber side.

6. Remove the oil seal (7) and spring seat (8).
7.  Remove the other valves in the same manner as described previously.

8. Remove the ect sensor (9).
9.  Remove the thermostat cover (10).

10. Remove the thermostat (11).
11. Remove the bypass hose union (12).

12. Remove the oil jet (13).

13. Remove the intake pipes (14).

14. Remove the oil gallery plug (15).
15.  Remove the cam chain tension adjuster service cap (16).

Assembly

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

•  tighten the cam chain tension adjuster service cap (1) and oil gallery plug (2) to the specified torque.

Tightening torque cam chain tension adjuster service cap (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft) oil gallery plug (cylinder head) (b): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

• Apply grease to o-rings of the intake pipes.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

• Install the intake pipes with the up mark “a” facing top side.
• Tighten the intake pipe bolts (3) to the specified torque.

Tightening torque intake pipe bolt (c): 8.5 N·m (0.85 Kgf-m, 6.5 Lbf-ft)

• Apply engine oil to the o-ring and install the oil jet.

• Apply bond to the thread part of bypass hose union (4) and tighten it to the specified torque.

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

Tightening torque bypass hose union (d): 12 n·m (1.2 Kgf-m, 8.5 Lbfft)

• Install the thermostat (5)

• Tighten the thermostat cover bolts (6) to the specified torque.

Tightening torque thermostat cover bolt (e): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

• Tighten the ect sensor (7) to the specified torque.

Tightening torque ect sensor (f): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft)

• Install the valve spring seat (8).
•  Apply molybdenum oil to the oil seal (9), and press-fit it into the position.

M/o: molybdenum oil (molybdenum oil solution)

• Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break.

M/o: molybdenum oil (molybdenum oil solution)

• Install each valve spring with the small-pitch portion “c” facing cylinder head.

• Put on the valve spring retainer (10), and using the special tools, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.

Special tool (a): 09916–14510 (valve lifter)
(b): 09916–14522 (valve lifter
attachment) (c): 09919–28620 (sleeve protector)
: 09916–84511 (tweezer)

• Be sure that the rounded lip “g” of the cotter fits snugly into the groove “h” in the stem end.

• Install the other valves and springs in the same manner as described previously.
• Install the tappet shims and the tappets to their original positions.