Cylinder Inspection; Cylinder Distortion; Piston Ring Removal And Installation; Piston-To-Cylinder Clearance - Suzuki GSX-R1000 Service Manual

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• Tighten the crankcase breather (PCV) cover bolts.
Engine Top Side
Assemble the engine top side. Refer to "Engine Top Side
Disassembly" (Page 1D-26).

Cylinder Inspection

Refer to "Engine Top Side Disassembly" (Page 1D-26).
Refer to "Engine Top Side Assembly" (Page 1D-28).

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)
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)
email: info@motomatrix.co.uk / www.motomatrix.co.uk
"A"
I947H1140215-03
B947H11406033

Piston-to-cylinder Clearance

Refer to "Piston and Piston Ring Inspection" (Page 1D-
71).

Piston Ring Removal and Installation

Removal
1) Remove the piston. Refer to "Engine Bottom Side
2) Carefully spread the ring opening with your thumbs
I947H1140216-01
3) Remove the 2nd ring and oil ring in the same
Engine Mechanical:
Disassembly" (Page 1D-49).
and then push up the opposite side of the 1st ring to
remove it.
NOTE
Do not expand the piston ring excessively
since it is apt to be broken down.
manner.
1D-69
(A)
I947H1140217-02
I837H1140180-01
B947H11406034
I837H1140181-01