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:
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
...
Fi system troubleshooting
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as
described by the customer. For this purpose,
use of such an inspection form such as following will facilitate collecting
information to the point required for proper
analysis and diagnosis.
...
Engine oil level check
Check the engine oil level as follows:
Place the motorcycle on level
ground on the side stand.
Start the engine and allow it to
idle for a few minutes.
Stop the engine and wait three
minutes.
Hold the motorcycle vertically
and check the oil level through
...