Engine Top Side Disassembly - Suzuki GSX-R1000 Service Manual

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1D-26 Engine Mechanical:
• Install the engine sprocket. Refer to "Engine Sprocket
Removal and Installation" in Section 3A (Page 3A-2).
• Install the exhaust pipe assembly and muffler. Refer to
"Muffler / Muffler Chamber / Exhaust Pipe Removal
and Installation" in Section 1K (Page 1K-11).
• Install the radiator. Refer to "Radiator / Cooling Fan
Motor Removal and Installation" in Section 1F
(Page 1F-6).
• Install the throttle body. Refer to "Throttle Body
Removal and Installation" (Page 1D-10).
• Install the air cleaner box. Refer to "Air Cleaner Box
Removal and Installation" (Page 1D-7).
• After remounting the engine, route the wiring harness,
cable and hoses properly. Refer to "Wiring Harness
Routing Diagram" in Section 9A (Page 9A-7), "Throttle
Cable Routing Diagram" (Page 1D-2) and "Water
Hose Routing Diagram" in Section 1F (Page 1F-3).
• Pour engine coolant and engine oil. Refer to "Cooling
System Inspection" in Section 0B (Page 0B-12) and
"Engine Oil and Filter Replacement" in Section 0B
(Page 0B-10).
• After finishing the engine installation, check the
following items.
– Throttle cable play
Refer to "Throttle Cable Play Inspection and
Adjustment" in Section 0B (Page 0B-12).
– 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 (Page 0B-14).
– Drive chain slack
Refer to "Drive Chain Inspection and Adjustment" in
Section 0B (Page 0B-14).
– Engine oil and coolant leakage
Refer to "Cooling Circuit Inspection" in Section 1F
(Page 1F-4).
email: info@motomatrix.co.uk / www.motomatrix.co.uk

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:
• Air cleaner box
• Throttle body
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" (Page 1D-20)
and "Engine Assembly Installation"
(Page 1D-24).
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
1) Remove the spark plugs. Refer to "Ignition Coil and
Spark Plug Removal and Installation" in Section 1H
(Page 1H-6).
2) Remove the cylinder head cover (1) and its gasket.
3) Remove the dowel pins and O-rings.
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