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:

Crankshaft journal bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect each upper and lower crankcase bearing for any damage. Set the crankshaft onto the upper crank case. Install the plastigauge onto each crankshaft jour ...

Engine coolant solution
Use engine coolant that is com· patible with an aluminum radiator, mixed with distilled water at a 50:50 mixture ratio for engine coolant solution. An engine coolant mixture other than 50:50 can affect cooling efficiency or rust inhibiting performance. Engine coolant Engine coolant should b ...

Throttle body inspection and cleaning
Refer to “throttle body disassembly and assembly” . Cleaning Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and sto ...