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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 : 0990020803 (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): 0990020530 (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:

Swingarm bearing removal and installation
Removal Remove the swingarm. Refer to swingarm removal and installation .  Remove the swingarm pivot bearings (1) using the special tool. Special tool (a): 0992120240 (bearing remover set) Remove the center spacer (2). Remove the cushion lever bearing (3) usin ...

Specifications
Service data Electrical unit: mm (in) Tightening torque specifications Reference: for the tightening torque of fastener not specified in this section, refer to tightening torque list in section 0c . ...

Brake pad
Front Rear Inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1. If a pad is worn to the grooved wear limit line, it must be replaced with a new one. After replacing either the front or rear brake pads, the brake lever or pedal must be ...

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