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:
Valve seat repair
The valve seats (1) for both the intake and exhaust
valves are machined to three different angles. The seat
contact surface is cut at 45°.
Intake valve
Exhaust valve
Caution
the valve seat contact area must be
inspected after e ...
Using the transmission
The transmission is provided to
keep the engine operating
smoothly in its normal operating
speed range. The gear ratios
have been carefully chosen to
meet the characteristics of the
engine. The rider should always
select the most suitable gear for
the prevailing conditions. Never
slip the c ...
Procedure for returning
to service
Clean the entire motorcycle.
Remove the oily rags from the
air cleaner intake and muffler
outlet.
Drain all the engine oil. Install
a new oil filter and fill the
engine with fresh oil as outlined
in this manual.
Remove the spark plugs. Turn
the engine a few tim ...