Suzuki GSX-R 1000 Service Manual: Engine top side assembly

Assemble the engine top side in the reverse order of disassembly. Pay attention to the following points:

Cylinder head

• Install the dowel pins and a new cylinder head gasket (1) to the cylinder.

• Place the cylinder head on the gasket.

• Tighten the cylinder head bolts (m10) to the specified torque with a torque wrench sequentially and diagonally.
• Additionally tighten the cylinder head bolts with the specified angles diagonally using an angular torque gauge.

Tightening torque cylinder head bolt (m10): 31 n·m (3.1 Kgf-m, 22.5 Lbf-ft) then turn in 1/6 (60°) turn

• After firmly tightening the cylinder head bolts (m10), tighten the cylinder head bolts (m6) (2).

Tightening torque cylinder head bolt (m6) (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

• Connect the water bypass hose (3).

Camshaft

• The camshafts are identified by the embossed letters.

  In: intake camshaft ex: exhaust camshaft

•  before placing the camshafts on the cylinder head, apply molybdenum oil to their journals, cam faces and holders.

M/o: molybdenum oil (molybdenum oil solution)

• Turn the crankshaft clockwise and align the line “a” on the ckp sensor rotor to the slit “b” of cap hole thread while keeping the cam chain pulled upward.

• Pull the cam chain lightly.
•  Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.

  (The exhaust camshaft sprocket has an arrow marked “1” “c”.)

•  Engage the cam chain with the exhaust camshaft sprocket.

• Bind the cam chain and the sprocket with a proper clamp (1) to prevent the cam chain disengagement while installing the camshaft journal holders.
•  The other arrow marked “2” “d” should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” “d”, count out 14 roller pins (from the exhaust camshaft side going towards the intake camshaft side).
•  Engage the 14th roller pin “e” on the cam chain with the arrow marked “3” on the intake camshaft sprocket.
•  Bind the cam chain and the sprocket with a proper clamp (2) to prevent the cam chain disengagement while installing the camshaft journal holders.

• Install the dowel pins.

• Install the camshaft journal holders and cam chain guide no. 2 (3).
•  Have the camshaft journal holders seated evenly by tightening the camshaft journal holder bolts lightly, in the ascending order of numbers.

• Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.

Tightening torque camshaft journal holder bolt: 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

• Remove the clamps.

Cam chain tension adjuster

• Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body until the outer circlip “a” reaches the groove “b”.

• Hook the outer circlip “a” into the groove “b”, then turn the plunger head clockwise more than 90° to make a little play in the inner thread mechanism.

• Fit a new gasket (1).

• Install the cam chain tension adjuster (2).

Tightening torque cam chain tension adjuster mounting bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

• Remove the cam chain tension adjuster service cap (3) and gasket (4).

• Unhook the outer circlip “a” from its groove by pushing the stepped part (5) of the plunger head with a screwdriver.
• Rotate the crankshaft (some turns) and recheck the valve timing.

• Tighten the cam chain tension adjuster service cap (6) to the specified torque.

Tightening torque cam chain tension adjuster service cap (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

• Tighten the valve timing inspection cap (7) to the specified torque.

Tightening torque valve timing inspection cap (c): 11 n·m (1.1 Kgfm, 8.0 Lbf-ft)

Cylinder head cover

• Check and adjust the valve clearance. Refer to “valve clearance inspection and adjustment” in section 0b .
•  Pour engine oil in each oil pocket on the cylinder head.
•  Install the dowel pins and o-rings.

• Install new gaskets to the cylinder head cover.
•  Apply bond to the cam end cap points of the gasket as shown.

: Sealant 99000–31140 (suzuki
bond no.1207B or equivalent)

• Place the cylinder head cover on the cylinder head.
•  Fit a new gasket (1) to each head cover bolt.

• Apply engine oil to both sides of the gaskets.

• Tighten the cylinder head cover bolts to the specified torque in two steps.

Tightening torque cylinder head cover bolt (initial): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft) cylinder head cover bolt (final): 14 n·m (1.4 Kgfm, 10.0 Lbf-ft)

• Install the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .