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:
Rear view mirror construction
Body cowling
Cowling brace
Cushion
Turn signal lead wire
Turn signal lead
wire coupler
: locate the turn signal lead wire coupler (5) between the
mirror cover (6) and mirror body (7).
Mirror cover
Mirror body
10 N·m (1.0 Kgf-m, 7.0 L ...
Specifications
Service data
Thermostat + radiator + fan + coolant
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Water hose routing diagram” “water pump components” “water
pump construction”
Reference: for the tig ...
Cylinder head cover related parts
inspection
Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Refer to “cylinder head cover disassembly and assembly” .
Cylinder head cover
Clean and check the gasket grooves “a” and pair reed
valve mating surfaces “b” of the cylinder head cover.
If there is anything unu ...