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:
Fastener removal and installation
Type a
Removal
Depress the head of fastener center piece (1).
Pull out the fastener (2).
Installation
Let the center piece stick out toward the head so that
the pawls “a” closes.
Insert the fastener into the installation hole.
Note
to prevent the pawl ...
Front seat
To remove the front seat.
Remove the bolts 1 (right and
left).
Raise the front end of the seat
and slide it forward.
To reinstall the seat, slide the seat
hooks into the seat hook retainers
on the frame and tighten the bolts
securely.
Warning
Failure to insta ...
Throttle cable play inspection and adjustment
Inspect throttle cable play
initially at 1 000 km (600 miles, 2 months) and every
6 000 km (4 000 miles, 12 months) thereafter
Inspect and adjust the throttle cable play “a” as follows:
Throttle cable play “a”
2.0 – 4.0 Mm (0.08 – 0.16 In)
Remove the boot (1).
Loosen the lock-nu ...