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Suzuki GSX-R 1000 Service Manual: 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


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:

Water pump construction
Impeller Mechanical seal Oil seal O-ring O-ring 8 N·m (0.8 Kgf-m, 6.0 Lbf-ft) 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) Apply grease. Apply engine coolant. Apply molybdenum oil solution. Do not reuse. ...

Ckp sensor removal and installation
Removal Remove the clutch cover. Refer to “clutch removal” in section 5c .  Remove the ckp sensor (1). Installation Install the ckp sensor in the reverse order of removal. Refer to “clutch installation” in section 5c . Iap sensor inspection Refer to “dtc “c13” (p0105-h/l): ia ...

Thermostat inspection
Inspect the thermostat in the following procedures:  remove the thermostat. Refer to “thermostat removal and installation” .  Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action. Caution  do not contact ...

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