Valve Seat Repair; Engine Bottom Side Disassembly; Crankcase Breather (Pcv) Cover; Starter Motor - Suzuki GSX-R1000 Service Manual

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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°.
45
60
30
1
[A]
[A]: Intake valve
Intake
Seat angle 30°/45°/60°
0.9 – 1.1 mm
Seat width
(0.035 – 0.043 in)
Valve 31.0 mm
diameter (1.22 in)
Valve guide 4.500 – 4.512 mm
I.D. (0.1772 – 0.1776 in)
CAUTION
!
• The valve seat contact area must be
inspected after each cut.
• Do not use lapping compound after the
final cut is made. The finished valve seat
should have a velvety smooth finish but
not a highly polished or shiny finish. This
will provide a soft surface for the final
seating of the valve which will occur
during the first few seconds of engine
operation.
• The titanium valves are coated with an
oxidized membrane treatment to resist
wear but the membrane tend to removed if
lapped after valve seat servicing.
NOTE
After servicing the valve seats, be sure to
check the valve clearance after the cylinder
head has been reinstalled. Refer to "Valve
Clearance Inspection and Adjustment" in
Section 0B (Page 0B-5).
email: info@motomatrix.co.uk / www.motomatrix.co.uk
B947H11406030
45
60
15
1
[B]
I837H1140069-01
[B]: Exhaust valve
Exhaust
15°/45°/60°
←
25.0 mm
(0.98 in)
←

Engine Bottom Side Disassembly

NOTE
The crankcase must be separated to service
the crankshaft and conrod.
1) Remove the engine assembly from the frame. Refer
to "Engine Assembly Removal" (Page 1D-20).
2) Remove the engine top side (1). Refer to "Engine
Top Side Disassembly" (Page 1D-26).

Crankcase Breather (PCV) Cover

Remove the crankcase breather (PCV) cover (1).

Starter Motor

Remove the starter motor (1).
Clutch
Remove the clutch component parts (1). Refer to "Clutch
Removal" in Section 5C (Page 5C-5).
1
Engine Mechanical: 1D-49
B947H11406031
1
I947H1140107-02
1
I947H1140108-03
I947H1140109-01