Suzuki GSX-R 1000 Service Manual: 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 engine, install the engine mounting thrust adjusters (2).

• Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft.

• Install all engine mounting bolts and tighten them temporarily.
• Tighten the engine mounting thrust adjusters (2) to the specified torque.

Tightening torque engine mounting thrust adjuster (a): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)

• Tighten the engine mounting thrust adjuster lock-nuts (3) to the specified torque with the special tool.

Tightening torque engine mounting thrust adjuster lock-nut (b): 45 n·m (4.5 Kgf-m, 32.5 Lbf-ft)

Special tool (a): 09940–14990 (engine mounting
adjust wrench)

• Tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration

• Tighten the engine mounting pinch bolt to the specified torque, as shown in the following illustration.

• Install the engine sprocket. Refer to “engine sprocket removal and installation” in section 3a .
•  Install the exhaust pipe assembly and muffler. Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k .
•  Install the radiator. Refer to “radiator / cooling fan motor removal and installation” in section 1f .
•  Install the throttle body. Refer to “throttle body removal and installation” .
•  Install the air cleaner box. Refer to “air cleaner box removal and installation” .
•  After remounting the engine, route the wiring harness, cable and hoses properly. Refer to “wiring harness routing diagram” in section 9a , “throttle cable routing diagram”  and “water hose routing diagram” in section 1f .
•  Pour engine coolant and engine oil. Refer to “cooling system inspection” in section 0b  and “engine oil and filter replacement” in section 0b .
•  After finishing the engine installation, check the following items.

•  Throttle cable play refer to “throttle cable play inspection and adjustment” in section 0b .
•  Throttle valve synchronization refer to “throttle valve synchronization” (page 1d- 16).
•  Clutch cable play refer to “clutch cable play inspection and adjustment” in section 0b .
•  Drive chain slack refer to “drive chain inspection and adjustment” in section 0b .
•  Engine oil and coolant leakage refer to “cooling circuit inspection” in section 1f .