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

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

Refer to engine top side disassembly .

Refer to engine top side assembly .

Caution

identify the position of each removed part.

Organize the parts in their respective groups (i.E., Intake, exhaust, no. 1 Or no. 2) So that they can be installed in their original locations.

Disassembly

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

Suzuki GSX-R. Disassembly


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

be careful not to damage the tappet sliding surface with the special tool.

Special tool (a): 0991928620 (sleeve protector)
(b): 0991614522 (valve lifter
attachment) (c): 0991614510 (valve lifter)
: 0991684511 (tweezer)


Suzuki GSX-R. Disassembly


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

Suzuki GSX-R. Disassembly


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

Suzuki GSX-R. Disassembly


  1. Remove the ect sensor (9).
  2.  Remove the thermostat cover (10).

Suzuki GSX-R. Disassembly


  1. Remove the thermostat (11).
  2. Remove the bypass hose union (12).

Suzuki GSX-R. Disassembly


  1. Remove the oil jet (13).

Suzuki GSX-R. Disassembly


  1. Remove the intake pipes (14).

Suzuki GSX-R. Disassembly


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

Suzuki GSX-R. Disassembly


Assembly

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

Caution

replace the gaskets with new ones.

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

Suzuki GSX-R. Assembly


Caution

replace the o-rings with new ones.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Assembly


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

Suzuki GSX-R. Assembly


Caution

use new o-ring to prevent oil pressure leakage

Suzuki GSX-R. Assembly


: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

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

Suzuki GSX-R. Assembly


Note

the air bleeder hole b of the thermostat faces upside.

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

Suzuki GSX-R. Assembly


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

Caution

  •  take special care when handling the temperature sensor. It may cause damage if it gets a sharp impact.
  •  Replace a gasket with a new one.

Suzuki GSX-R. Assembly


Caution

do not reuse the removed oil seal.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Assembly


Caution

when inserting the valve, take care not to damage the lip of the oil seal.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


  1. Small-pitch portion
  2. Large-pitch portion
  3. Upward
  4. Paint
Caution

  •  be sure to restore each spring and valve to their original positions.
  •  Be careful not to damage the valve and valve stem when handling them.
  •  Be careful not to damage the tappet sliding surface with the special tool.

Special tool (a): 0991614510 (valve lifter)
(b): 0991614522 (valve lifter
attachment) (c): 0991928620 (sleeve protector)
: 0991684511 (tweezer)


Suzuki GSX-R. Assembly


Suzuki GSX-R. Assembly


  1. Valve spring retainer
  2. Cotter
Note

  •  apply engine oil to the stem end, shim and tappet before fitting them.
  •  When seating the tappet shim, be sure the figure printed surface faces the tappet.

Suzuki GSX-R. Assembly


Cam chain tensioner inspection
Inspect the cam chain tensioner in the following procedures:  remove the cam chain tensioner. Refer to cam chain guide / cam chain tensioner removal and installation .  Check the ...

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 ...

Other materials:

Gearshift linkage inspection
Refer to gearshift shaft / gearshift cam plate removal and installation . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...

Air bleeding from brake fluid circuit
Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by sponginess of the brake lever and also by la ...

Fuel pump components
Fuel level gauge Fuel pressure regulator assembly O-ring Joint Fuel pump Fuel pump case Fuel mesh filter 10 Nm (1.0 Kgf-m, 7.0 Lbf-ft) Apply engine oil. Apply grease. Do not reuse. ...

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