Suzuki GSX-R 1000 Service Manual: 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 it.
| Note do not expand the piston ring excessively since it is apt to be broken down. |
- Remove the 2nd ring and oil ring in the same manner.
Installation
Note
|
- Install the piston rings in the order of the oil ring, second ring and top ring.
- the first member to go into the oil ring groove is
the spacer (1).
After placing the spacer, fit the two side rails (2).
| Caution when installing the spacer, be careful not to allow its two ends to overlap in the groove. |
|
- Install the 2nd ring (3) and 1st ring (4) to piston.
| Note 1st ring (4) and 2nd ring (3) differ in shape. |
| Note face the side with the stamped mark upward when assembling. |
- Position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, check that the gaps are so located.
|
- Install each piston and piston pin. Refer to “engine bottom side assembly” .
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 gau ...
Piston and piston ring inspection
Refer to “piston ring removal and installation” .
Piston diameter
Measure the piston diameter using the micrometer at 15
mm (0.6 In) “a” from the skirt end. If the piston diameter
is less than the ...
Other materials:
Front fork removal and installation
Note
the right and left front forks are installed
symmetrically and therefore the removal
procedure for one side is the same as that for
the other side.
Removal
Remove the front wheel. Refer to “front wheel assembly removal and
installation” in section 2d .
...
Engine top side disassembly
It is unnecessary to remove the engine assembly from
the frame when servicing the cylinder head cover and
camshafts.
Note
before servicing the engine top side
components (until camshafts removal) with
the engine in place, remove the following
parts:
air cleaner box
...
Fuel pump relay inspection
Refer to “electrical components location” in section 0a .
Inspect the fuel pump relay in the following procedures:
remove the frame covers. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Remove the fuel pump relay (1).
First, check f ...