Suzuki GSX-R 1000 Service Manual: Cylinder inspection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Cylinder inspection

Refer to “engine top side disassembly” .

Refer to “engine top side assembly” .

Cylinder distortion

Check the gasket surface of the cylinder for distortion.

Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the crankcase set.

Special tool : 09900–20803 (thickness gauge)

Cylinder distortion service limit: 0.02 Mm (0.0008 In)

Suzuki GSX-R. Cylinder distortion

Cylinder bore

Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston.

The remaining cylinders must also be rebored accordingly; otherwise, the imbalance might cause excessive vibration.

Special tool (a): 09900–20530 (cylinder gauge set)

Cylinder bore standard: 74.500 – 74.515 Mm (2.9331 – 2.9337 In)

Suzuki GSX-R. Cylinder bore

Piston-to-cylinder clearance

Refer to “piston and piston ring inspection” (page 1d- 71).

Engine bottom side assembly

Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: Note apply engine oil to each running and sliding part before reassembling. ...

Piston ring removal and installation

Removal Remove the piston. Refer to “engine bottom side disassembly” . Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove i ...

Other materials:

Isc valve preset and opening initialization
When removing or replacing the isc valve, set the isc valve to the following procedures: turn the ignition switch on. Set up the sds tool. (Refer to the sds operation manual for further details.) Click the “active control”. Click the “isc learned value reset” (1) ...

Oil pressure indicator inspection
Inspect the oil pressure indicator in the following procedures: Note before inspecting the oil pressure switch, check if the engine oil level is correct. Refer to “engine oil and filter replacement” in section 0b . Remove the left side cowling. Refer to “exterior parts remov ...

Exhaust pipe bolt and muffler bolt inspection
Tighten exhaust pipe bolts and muffler bolts initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Check the exhaust pipe bolts and muffler bolts to the specified torque. Tightening torque exhaust pipe bolt (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft) muf ...