Suzuki GSX-R 1000 Service Manual: 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:
Other parts except for these “engine top side components” can not be serviced with the engine installed in the frame. Refer to “engine assembly removal” and “engine assembly installation” . |
| Caution identify the position of each removed part. Organize the parts in their respective groups (e.G., Intake, exhaust) so that they can be reinstalled in their original positions. |
Cylinder head cover
- Remove the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .
- Remove the cylinder head cover (1) and its gasket.
- Remove the dowel pins and o-rings.
Camshafts
- Remove the valve timing inspection cap (1).
- Turn the crankshaft to bring the line “a” on the ckp sensor rotor to the slit “b” of cap hole thread and also to bring the camshafts to the position as shown.
- Remove the cam chain tension adjuster (2).
- Remove the gasket (3).
- Remove the cam chain guide no. 2 (4).
- Remove the camshaft journal holders (5).
| Caution be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers. |
- Remove the dowel pins.
- Remove the intake camshaft (6) and exhaust camshaft (7).
Cylinder head
| Note the cylinder head can not be serviced with the engine installed in the frame. |
- Disconnect the water bypass hose (1).
- Remove the cylinder head bolts (m6) (2).
- Remove the cylinder head bolts (m10) and washers.
| Note when loosening the cylinder head bolts, loosen each bolt little by little diagonally. |
- Remove the cylinder head.
- Remove the dowel pins and cylinder head gasket (3).
Engine assembly installation
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
before installing the engine, install the collars (1).
Before installing the en ...
Engine top side assembly
Assemble the engine top side in the reverse order of
disassembly. Pay attention to the following points:
Cylinder head
Install the dowel pins and a new cylinder head gasket
(1) to the cylinder ...
Other materials:
Gearshift lever height inspection and
adjustment
Inspect and adjust the gearshift lever height in the
following procedures:
inspect the gearshift lever height “a” between the
lever top and footrest.
Adjust the gearshift lever height if necessary.
Gearshift lever height “a”
standard: 65 – 75 mm (2.6 – 3.0 In)
Loosen the l ...
Engine sprocket removal and installation
Removal
Remove the gearshift link arm (1) from the gearshift
shaft.
Note
mark the gearshift shaft head at which the
gearshift link arm slit set for correct
reinstallation.
Remove the speed sensor (2).
Remove the engine sprocket cover (3).
Support the ...
Radiator cap inspection
Inspect the radiator cap in the following procedures:
remove the radiator cap. Refer to “cooling circuit inspection” .
Attach the radiator cap (1) to the radiator tester (2)
as shown.
Slowly apply pressure to the radiator cap.
If the radiator cap does not hold the pre ...