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Suzuki GSX-R 1000 Service Manual: 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 gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the crankcase set.

Special tool : 09900–20803 (thickness gauge)

Cylinder distortion service limit: 0.02 Mm (0.0008 In)

Suzuki GSX-R. Cylinder distortion


Cylinder bore

Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston.

The remaining cylinders must also be rebored accordingly; otherwise, the imbalance might cause excessive vibration.

Special tool (a): 09900–20530 (cylinder gauge set)

Cylinder bore standard: 74.500 – 74.515 Mm (2.9331 – 2.9337 In)

Suzuki GSX-R. Cylinder bore


Suzuki GSX-R. Cylinder bore


Piston-to-cylinder clearance

Refer to “piston and piston ring inspection” (page 1d- 71).

Engine bottom side assembly
Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: Note apply engine oil to each running and sliding part before reassembling. ...

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 i ...

Other materials:

Rear lighting system construction
License plate light assembly Reflex reflector (e-03, 28, 33 only) Clamp : clamp the license plate light lead wire so as not to be slack. Rear combination light Rear turn signal light assembly (lh/rh) 5 N·m (0.5 Kgf-m, 3.5 Lbf-ft) 1.8 N·m ...

Drive chain inspection and adjustment
Inspect drive chain initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Drive chain visual check With the transmission in neutral, support the motorcycle using a jack and turn the rear wheel slowly by hand. Visually check the drive chain fo ...

Rear seat
The seat lock is located under the left frame cover. To remove the rear seat, insert the ignition key into the lock and turn it clockwise. Raise the front end of the seat and slide it forward. To reinstall the seat, slide the seat hooks into the seat hook retainers and push down firm ...

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