Suzuki GSX-R 1000 Service Manual: Valve guide replacement
- Remove the cylinder head. Refer to “engine top side disassembly” .
- Remove the valves. Refer to “cylinder head disassembly and assembly” .
- Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.
Special tool
(a): 09916–43211 (valve guide
installer &
remover)
Note
|
- Refinish the valve guide holes in the cylinder head using the reamer and handle.
| Caution when refinishing or removing the reamer from the valve guide hole, always turn it clockwise. |
Special tool
(b): 09916–33320 (valve guide reamer
(9.8
Mm))
(c): 09916–34542 (reamer handle)
- Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot plate.
| Caution do not use a burner to heat the valve guide hole to prevent cylinder head distortion. |
- Apply engine oil to each valve guide and valve guide hole.
- Drive the guide into the guide hole using the valve guide installer.
| Caution failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head. |
Special tool
(a): 09916–43211 (valve guide
installer &
remover)
(d): 09916–53380 (valve guide
installer
attachment)
|
- After installing the valve guides, refinish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming.
Note
|
Special tool
(c): 09916–34542 (reamer handle)
(e): 09916–33210 (valve guide reamer
(4.5
Mm))
- Reassemble the cylinder head. Refer to “cylinder head disassembly and assembly” .
- Install the cylinder head assembly. Refer to “engine top side assembly” .
Cylinder head related parts inspection
Refer to “cylinder head disassembly and assembly” .
Cylinder head distortion
Decarbonize the combustion chambers.
Check the gasket surface of the cylinder head for
distortion. Use a str ...
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
...
Other materials:
Throttle body components
Fuel delivery pipe
Fuel delivery pipe t-joint
O-ring
Tp sensor
Stp sensor
Secondary fuel injector
Primary fuel injector
Cushion seal
Isc valve
Air screw
Vacuum hose
Evap system purge control solenoid valve
For e-33 only
3.5
...
Wiring harness routing diagram
Wiring harness no. 2
Tapping clamp
: insert the clamp from the front side. Place the turn signal
and position light couplers in front of the clamp.
Steel clamp
: clamp the wiring harness at the blue taping point. Bend
the steel clamps to the front side.
...
Foreword
Motorcycling is one of the most
exhilarating sports and to ensure
your riding enjoyment, you should
become thoroughly familiar with
the information presented in this
owner's manual before riding the
motorcycle.
The proper care and maintenance
that your motorcycle requires is
outlined in t ...