Suzuki GSX-R1000. Service Manual

1D-76 Engine Mechanical:

4) Check the corresponding crankcase journal I.D.

code number “A”, [A], [B] or [C] which is stamped on
the rear of upper crankcase.

Bearing selection table

Crankcase I.D. specification

Balancer shaft journal O.D. specification
19.992 – 20.000 mm (0.7871 – 0.7874 in)

Bearing thickness specification

NOTE

The balancer shaft journal bearings on upper
and lower crankcases are the same.

Conrod Crank Pin Bearing Removal and
Installation

B947H11406040

Refer to “Engine Bottom Side Disassembly” (Page 1D-
49).
Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Removal

Remove the conrod crank pin bearings (1).

NOTE

• Do not remove the bearings (1) unless

absolutely necessary.

• Make a note of where the bearings are

removed from so that they can be
reinstalled in their original positions.

CAUTION

When removing the bearings, be careful not
to scratch the conrods and the bearings.

Installation

When installing the bearings into the conrod cap and
conrod, be sure to install the tab “A” first, and then press
in the other opposite side of the bearing.

NOTE

Inspect and select the conrod crank pin
bearing if necessary. Refer to “Conrod Crank
Pin Bearing Inspection and Selection”
(Page 1D-78).

Crankcase I.D. “A”

Green

Black

Brown

Code

I.D. specification

23.000 – 23.008 mm

(0.9055 – 0.9058 in)

23.008 – 23.016 mm

(0.9058 – 0.9061 in)

23.016 – 23.024 mm

(0.9061 – 0.9065 in)

Color (Part No.)

Thickness

Green

(12229-47H00-0A0)

1.482 – 1.486 mm

(0.0583 – 0.0585 in)

Black

(12229-47H00-0B0)

1.486 – 1.490 mm

(0.0585 – 0.0587 in)

Brown

(12229-47H00-0C0)

1.490 – 1.494 mm

(0.0587 – 0.0588 in)

“A”

I947H1140233-01

I947H1140234-01

I718H1140269-01

“A”

I823H1140578-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-77

Conrod and Crankshaft Inspection

B947H11406041

Refer to “Engine Bottom Side Disassembly” (Page 1D-
49).
Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Conrod Small End I.D.

Measure the conrod small end inside diameter using the
small bore gauge.
If the conrod small end inside diameter exceeds the
service limit, replace the conrod.

Special tool

(A): 09900–20602 (Dial gauge)
(B): 09900–22401 (Small bore gauge (10 – 18

mm))

Conrod small end I.D.
Service limit: 15.040 mm (0.5921 in)

Conrod Big End Side Clearance

1) Check the conrod big end side clearance using the

thickness gauge.

Special tool

(A): 09900–20803 (Thickness gauge)

Conrod big end side clearance
Service limit: 0.30 mm (0.012 in)

2) If the clearance exceeds the limit, remove the conrod

and measure the conrod big end width and crank pin
width. Refer to “Engine Bottom Side Assembly”
(Page 1D-56). If any of the measurements are out of
specification, replace the conrod or crankshaft.

Special tool

(B): 09900–20205 (Micrometer (0 – 25 mm))
(C): 09900–20605 (Dial calipers (10 – 34

mm))

Conrod big end width
Standard: 19.95 – 20.00 mm (0.7854 – 0.7874 in)

Crank pin width
Standard: 20.10 – 20.15 mm (0.7913 – 0.7933 in)

Crankshaft Runout

Support the crankshaft using V-blocks as shown, with
the two end journals resting on the blocks. Set up the
dial gauge as shown, and rotate the crankshaft slowly to
read the runout. Replace the crankshaft if the runout
exceeds the service limit.

Special tool

(A): 09900–20607 (Dial gauge)
(B): 09900–20701 (Dial gauge chuck)
(C): 09900–21304 (V blocks)

Crankshaft runout
Service limit: 0.05 mm (0.002 in)

(B)

(A)

I823H1140280-01

(A)

I823H1140281-01

(B)

(C)

I823H1140282-01

(A)

(B)

(C)

I947H1140235-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1D-78 Engine Mechanical:

Conrod Crank Pin Bearing Inspection and
Selection

B947H11406042

Refer to “Engine Bottom Side Disassembly” (Page 1D-
49).
Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) Inspect the bearing surfaces for any signs of fusion,

pitting, burn or flaws. If any, replace them with a
specified set of bearings.

2) Place the plastigauge axially along the crank pin,

avoiding the oil hole, as shown in the figure.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076

mm))

3) Tighten the conrod cap bolts to the specified torque,

in two stages.

NOTE

• When installing the conrod cap bolts to the

crank pin, make sure that I.D code “A” on
the conrod faces towards the intake side.

• Never rotate the crankshaft or conrod

when a piece of plastigauge is installed.

Tightening torque
Conrod cap bolt: 37 N

⋅

m (3.7 kgf-m, 26.5 Ib-ft)

then turn in 1/6 (60

) turn

4) Remove the conrod cap bolts and measure the width

of the compressed plastigauge using the envelope
scale. This measurement should be taken at the
widest part of the compressed plastigauge.
If the oil clearance exceeds the service limit, select
the specified bearings from the bearing selection
table.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076

mm))

Conrod big end oil clearance
Standard: 0.040 – 0.064 mm (0.0016 – 0.0025 in)

Conrod big end oil clearance
Service limit: 0.080 mm (0.0031 in)

Selection

1) Check the corresponding conrod I.D. code numbers

([1] or [2]) “A”.

Conrod I.D. specification

I718H1140285-01

(A)

I718H1140286-01

“A”

I823H1140284-01

Code “A”

I.D. specification

38.000 – 38.008 mm

(1.4961 – 1.4964 in)

38.008 – 38.016 mm

(1.4964 – 1.4967 in)

(A)

I718H1140289-01

“A”

I718H1140290-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-79

2) Check the corresponding crank pin O.D. code

numbers ([1], [2] or [3]) “B”.

3) Measure the conrod crank pin O.D. with the special

tool. If any of the measurements are out of
specification, replace the crankshaft.

Crank pin O.D. specification

Special tool

(A): 09900–20202 (Micrometer (25 – 50

mm))

4) Select the specified bearings from the bearing

selection table.

CAUTION

The bearings should be replaced as a set.

Bearing selection table

Bearing thickness specification

Crankshaft Journal Bearing Inspection and
Selection

B947H11406043

Refer to “Engine Bottom Side Disassembly” (Page 1D-
49).
Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) Inspect each upper and lower crankcase bearing for

any damage.

Code “B”

O.D. specification

34.992 – 35.000 mm

(1.3776 – 1.3780 in)

34.984 – 34.992 mm

(1.3773 – 1.3776 in)

34.976 – 34.984 mm

(1.3770 – 1.3773 in)

“B”

I947H1140236-01

(A)

I823H1140286-01

Conrod
I.D. “A”

”

Code

Green

Black

Brown

Yellow

Crank pin O.D. “B

I718H1140293-01

Color “C” (Part No.)

Thickness

Yellow

(12164-47H00-0D0)

1.488 – 1.492 mm

(0.0586 – 0.0587 in)

Brown

(12164-47H00-0C0)

1.484 – 1.488 mm

(0.0584 – 0.0586 in)

Black

(12164-47H00-0B0)

1.480 – 1.484 mm

(0.0583 – 0.0584 in)

Green

(12164-47H00-0A0)

1.476 – 1.480 mm

(0.0581 – 0.0583 in)

“C”: Color code

“C”

I823H1140595-01

I947H1140237-01

I947H1140238-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1D-80 Engine Mechanical:

2) Set the crankshaft onto the upper crank case.

3) Install the plastigauge onto each crankshaft journal.

Special tool

(A): 09900–22301 (Plastigage (0.025 – 0.076

mm))

4) Mate the lower crankcase with the upper crankcase.

5) Tighten the crankshaft journal bolts (M9). Tighten

each bolt a little at a time to equalize the pressure in
the following two steps.

NOTE

Do not rotate the crankshaft when a piece of
plastigauge is installed.

Tightening torque
Crankshaft journal bolt (M9): 18 N

⋅

m (1.8 kgf-m,

13.0 lbf-ft) then turn in 50

6) Remove the lower crankcase and measure the width

of compressed plastigauge using the envelope
scale. This measurement should be taken at the
widest part of the compressed plastigauge. If the oil
clearance exceeds the service limit, select the
specified bearings from the bearing selection table.

Crankshaft journal oil clearance
Standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in)

Crankshaft journal oil clearance
Service limit: 0.080 mm (0.0031 in)

Selection

1) Check the corresponding crankcase journal I.D.

codes “A” ([A], [B] or [C]), which are stamped on the
rear of the upper crankcase.

Crankcase journal I.D. specification

(A)

I947H1140239-01

I947H1140240-01

Code “A”

I.D. specification

38.000 – 38.006 mm

(1.4961 – 1.4963 in)

38.006 – 38.012 mm

(1.4963 – 1.4965 in)

38.012 – 38.018 mm

(1.4965 – 1.4968 in)

I947H1140241-01

“A”

I947H1140242-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-81

2) Check the corresponding crankshaft journal O.D.

codes “B” ([A], [B] or [C]), which are stamped on the
crankshaft.

3) Measure the crankshaft O.D. with the special tool. If

any of the measurements are out of specification,
replace the crankshaft.

Crankshaft journal O.D. specification

Special tool

(A): 09900–20202 (Micrometer (25 – 50

mm))

4) Select the specified bearings from the bearing

selection table.

Bearing selection table

Bearing thickness specification

Code “B”

O.D. specification

34.994 – 35.000 mm

(1.3777 – 1.3780 in)

34.988 – 34.994 mm

(1.3775 – 1.3777 in)

34.982 – 34.988 mm

(1.3772 – 1.3775 in)

“B”

I947H1140243-01

(A)

I947H1140244-01

Color “C” (Part No.)

Thickness

Blue

(12229-47H10-0E0)

1.501 – 1.504 mm

(0.0591 – 0.0592 in)

Yellow

(12229-47H10-0D0)

1.498 – 1.501 mm

(0.0590 – 0.0591 in)

Brown

(12229-47H10-0C0)

1.495 – 1.498 mm

(0.0589 – 0.0590 in)

Black

(12229-47H10-0B0)

1.492 – 1.495 mm

(0.0587 – 0.0589 in)

Green

(12229-47H10-0A0)

1.489 – 1.492 mm

(0.0586 – 0.0587 in)

“C”: Color code

Crankcase

I.D. “A”

Crankshaft O.D. “B”

Code

Green

Black

Brown

Yellow

Brown

Yellow

Blue

I823H1140299-01

“C”

I947H1140245-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1D-82 Engine Mechanical:

Crankshaft Thrust Clearance Inspection and
Selection

B947H11406044

Refer to “Engine Bottom Side Disassembly” (Page 1D-
49).
Refer to “Engine Bottom Side Assembly” (Page 1D-56).

Inspection

1) With the crankshaft’s right-side and left-side thrust

bearings inserted into the upper crankcase.

2) Measure the thrust clearance “a” between the left-

side thrust bearing and crankshaft using the
thickness gauge. If the thrust clearance exceeds the
standard range, adjust the thrust clearance.

NOTE

Pull the crankshaft to the left (generator side)
so that there is no clearance on the right-side
thrust bearing.

Special tool

: 09900–20803 (Thickness gauge)

Crankshaft thrust clearance “a”
Standard: 0.060 – 0.110 mm (0.0024 – 0.0043 in)

Selection

1) Remove the right-side thrust bearing and measure

its thickness using the micrometer. If the thickness of
the right-side thrust bearing is below standard,
replace it with a new bearing and measure the thrust
clearance again, as described in Inspection 1) and
2).

Special tool

(A): 09900–20205 (Micrometer (0 – 25 mm))

Right-side thrust bearing thickness
Standard: 2.420 – 2.440 mm (0.0953 – 0.0961 in)

2) If the right-side thrust bearing is within the standard

range, reinsert the right-side thrust bearing and
remove the left-side thrust bearing.

3) With the left-side thrust bearing removed, measure

the clearance “a” using the thickness gauge as
shown.

Special tool

(B): 09900–20803 (Thickness gauge)

1. Right-side thrust bearing

“A”: Front side

2. Left-side thrust bearing

“B”: Left side

“A”

“B”

I947H1140248-01

“ a ”

(A)

I837H1140197-02

(A)

I649G1140343-02

“ a ”

(B)

I837H1140198-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-83

4) Select a left-side thrust bearing from the selection table.

NOTE

Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) of left-side
thrust bearing.

Thrust bearing selection table

5) After selecting a left-side thrust bearing, install it and then measure the thrust clearance again.

Clearance before inserting

left-side thrust bearing

Color “A” (Part No.)

Thrust bearing thickness

Thrust clearance

2.570 – 2.590 mm

(0.1012 – 0.1020 in)

Brown

(12228-48B00-0B0)

2.480 – 2.500 mm

(0.0976 – 0.0984 in)

0.070 – 0.110 mm

(0.0028 – 0.0043 in)

2.550 – 2.570 mm

(0.1004 – 0.1012 in)

Red

(12228-48B00-0C0)

2.460 – 2.480 mm

(0.0969 – 0.0976 in)

2.530 – 2.550 mm

(0.0996 – 0.1004 in)

Yellow

(12228-48B00-0D0)

2.440 – 2.460 mm

(0.0961 – 0.0969 in)

2.510 – 2.530 mm

(0.0988 – 0.0996 in)

Green

(12228-48B00-0E0)

2.420 – 2.440 mm

(0.0953 – 0.0961 in)

2.490 – 2.510 mm

(0.0980 – 0.0988 in)

Blue

(12228-48B00-0F0)

2.400 – 2.420 mm

(0.0945 – 0.0953 in)

2.470 – 2.490 mm

(0.0972 – 0.0980 in)

Orange

(12228-48B00-0G0)

2.380 – 2.400 mm

(0.0937 – 0.0945 in)

2.440 – 2.470 mm

(0.0961 – 0.0972 in)

Black

(12228-48B00-0H0)

2.360 – 2.380 mm

(0.0929 – 0.0937 in)

0.060 – 0.110 mm

(0.0024 – 0.0043 in)

“A”: Color code

“A”

I649G1140345-02

-------------------------------------------------------------------------------------------------------------------------------------------------------------

1D-84 Engine Mechanical:

Specifications

Service Data

B947H11407001

Valve + Guide

Unit: mm (in)

Camshaft + Cylinder Head

Unit: mm (in)

Item

Standard

Limit

Valve diam.

IN.

31.0 (1.22)

—

EX.

25.0 (0.98)

—

Valve clearance (when cold)

IN.

0.08 – 0.18 (0.003 – 0.007)

—

EX.

0.18 – 0.28 (0.007 – 0.011)

—

Valve guide to valve stem clearance

IN.

0.010 – 0.037 (0.0004 – 0.0015)

—

EX.

0.030 – 0.057 (0.0012 – 0.0022)

—

Valve guide I.D.

IN. & EX.

4.500 – 4.512 (0.1772 – 0.1776)

—

Valve stem O.D.

IN.

4.475 – 4.490 (0.1762 – 0.1768)

—

EX.

4.455 – 4.470 (0.1754 – 0.1760)

—

Valve stem deflection

IN. & EX.

—

0.25 (0.010)

Valve stem runout

IN. & EX.

—

0.05 (0.002)

Valve seat width

IN. & EX.

0.9 – 1.1 (0.035 – 0.043)

—

Valve head radial runout

IN. & EX.

—

0.03 (0.001)

Valve spring free length

Inner

—

30.1 (1.19)

Outer

—

35.3 (1.39)

Valve spring tension

Inner

31.3 – 38.3 N (3.2 – 3.9 kgf, 7.0 – 8.6 lbs)

at length 27.55 mm (1.085 in)

—

Outer

91.3 – 105.1 N (9.3 – 10.7 kgf, 20.5 – 23.6 lbs)

at length 33.05 mm (1.301 in)

—

Item

Standard

Limit

Cam height

IN.

37.68 – 37.73 (1.483 – 1.485)

37.38 (1.472)

EX.

36.88 – 36.93 (1.452 – 1.454)

36.58 (1.440)

Camshaft journal oil clearance

IN. & EX.

0.032 – 0.066 (0.0013 – 0.0026)

0.150 (0.0059)

Camshaft journal holder I.D.

IN. & EX.

24.012 – 24.025 (0.9454 – 0.9459)

—

Camshaft journal O.D.

IN. & EX.

23.959 – 23.980 (0.9433 – 0.9441)

—

Camshaft runout

—

0.10 (0.004)

Cam chain pin (at arrow “3”)

14th pin

—

Cylinder head distortion

—

0.02 (0.0008)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-85

Cylinder + Piston + Piston Ring

Unit: mm (in)

Conrod + Crankshaft

Unit: mm (in)

Balancer

Unit: mm (in)

Throttle Body

Item

Standard

Limit

Compression pressure

1 400 – 1 800 kPa (14 – 18 kgf/cm

, 199 – 256 psi)

1 000 kPa

(10 kgf/cm

142 psi)

Compression pressure difference

—

200 kPa

(2 kgf/cm

, 28 psi)

Piston-to-cylinder clearance

0.030 – 0.040 (0.0012 – 0.0016)

0.120 (0.0047)

Cylinder bore

74.500 – 74.515 (2.9331 – 2.9337)

Nicks or scratches

Piston diam.

74.465 – 74.480 (2.9317 – 2.9323)

Measure 10 mm (0.4 in) from the skirt end.

74.380 (2.9283)

Cylinder distortion

—

0.02 (0.0008)

Piston ring free end gap

1st

Approx. 7.0 (0.28)

5.6 (0.22)

2nd

Approx. 8.0 (0.32)

6.4 (0.25)

Piston ring end gap

1st

0.06 – 0.18 (0.002 – 0.007)

0.50 (0.020)

2nd

0.06 – 0.18 (0.002 – 0.007)

0.50 (0.020)

Piston ring-to-groove clearance

1st

—

0.180 (0.0071)

2nd

—

0.150 (0.0059)

Piston ring groove width

1st

0.83 – 0.85 (0.0327 – 0.0335)
1.30 – 1.32 (0.0512 – 0.0520)

—

2nd

0.81 – 0.83 (0.0319 – 0.0327)

—

Oil

1.51 – 1.53 (0.0594 – 0.0602)

—

Piston ring thickness

1st

0.76 – 0.81 (0.0299 – 0.0319)
1.08 – 1.10 (0.0425 – 0.0433)

—

2nd

0.77 – 0.79 (0.0303 – 0.0311)

—

Piston pin bore

15.002 – 15.008 (0.5906 – 0.5909)

15.030 (0.5917)

Piston pin O.D.

14.995 – 15.000 (0.5903 – 0.5512)

14.980 (0.5898)

Item

Standard

Limit

Conrod small end I.D.

15.010 – 15.018 (0.5909 – 0.5913)

15.040 (0.5921)

Conrod big end side clearance

0.10 – 0.20 (0.004 – 0.008)

0.30 (0.012)

Conrod big end width

19.95 – 20.00 (0.7854 – 0.7874)

—

Crank pin width

20.10 – 20.15 (0.7913 – 0.7933)

—

Conrod big end oil clearance

0.040 – 0.064 (0.0016 – 0.0025)

0.080 (0.0031)

Crank pin O.D.

34.976 – 35.000 (1.3770 – 1.3780)

—

Crankshaft journal oil clearance

0.016 – 0.034 (0.0006 – 0.0013)

0.080 (0.0031)

Crankshaft journal O.D.

34.982 – 35.000 (1.3772 – 1.3780)

—

Crankshaft thrust bearing thickness

Right side

2.420 – 2.440 (0.0953 – 0.0961)

—

Left side

2.360 – 2.500 (0.0929 – 0.0984)

—

Crankshaft thrust clearance

0.060 – 0.110 (0.0024 – 0.0043)

—

Crankshaft runout

—

0.05 (0.002)

Item

Standard

Limit

Balancer shaft journal oil clearance

0.028 – 0.052 (0.0011 – 0.0020)

0.080 (0.0031)

Balancer shaft journal O.D.

19.992 – 20.000 (0.7871 – 0.7874)

—

Item

Specification

Bore size

44 mm (1.73 in)

I.D. No.

47H1 (For E-33), 47H0 (For others)

Idle r/min

1 150

100 r/min

Throttle cable play

2.0 – 4.0 mm (0.08 – 0.16 in)

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1D-86 Engine Mechanical:

Tightening Torque Specifications

B947H11407002

Fastening part

Tightening torque

Note

⋅

kgf-m

lbf-ft

Throttle cable lock-nut

4.5

0.45

3.0

)

(Page 1D-11)

STP sensor mounting screw

3.5

0.35

2.5

)

(Page 1D-13)

TP sensor mounting screw

3.5

0.35

2.5

)

(Page 1D-14)

ISC valve mounting screw

0.2

1.5

)

(Page 1D-14)

Fuel delivery pipe mounting screw

3.5

0.35

2.5

)

(Page 1D-15)

Engine mounting thrust adjuster

2.3

16.5

)

(Page 1D-24)

Engine mounting thrust adjuster lock-nut

4.5

32.5

)

(Page 1D-24)

Cylinder head bolt (M10)

31 N

⋅

m (3.1 kgf-m, 22.5 lbf-ft) then turn in 1/

6 (60

) turn

)

(Page 1D-29)

Cylinder head bolt (M6)

1.0

7.0

)

(Page 1D-29)

Camshaft journal holder bolt

1.0 7.0

Cam chain tension adjuster mounting bolt

1.0

7.0

)

(Page 1D-33)

Cam chain tension adjuster service cap

2.3 16.5

Valve timing inspection cap

1.1

8.0

)

(Page 1D-34)

Cylinder head cover bolt (Initial)

1.0

7.0

)

(Page 1D-35)

Cylinder head cover bolt (Final)

1.4

10.0

)

(Page 1D-35)

CMP sensor bolt

1.0

7.0

)

(Page 1D-35)

PAIR reed valve cover bolt

1.0

7.0

)

(Page 1D-36)

Oil gallery plug (Cylinder head)

1.0

7.0

)

(Page 1D-42)

Intake pipe bolt

8.5

0.85

6.5

)

(Page 1D-42)

Bypass hose union

1.2

8.5

)

(Page 1D-42)

Thermostat cover bolt

1.0

7.0

)

(Page 1D-43)

ECT sensor

1.8

13.0

)

(Page 1D-43)

Water jacket plug

9.5

0.95

6.9

)

(Page 1D-57)

Oil gallery plug (M10)

1.8

13.0

)

(Page 1D-57)

Oil gallery plug (M12)

1.5

11.0

)

(Page 1D-57)

Oil gallery plug (M26)

1.1

8.0

)

(Page 1D-57)

Oil gallery plug (M6)

1.0

7.0

)

(Page 1D-57)

Piston cooling oil jet bolt

1.0

7.0

)

(Page 1D-59)

Conrod cap bolt

37 N

⋅

m (3.7 kgf-m, 26.5 lbf-ft) then turn in 1/

6 (60

) turn

Crankshaft journal bolt (M9)

18 N

⋅

m (1.8 kgf-m, 13.0 lbf-ft) then turn in

Crankcase bolt (M8) (Initial)

1.5 11.0

Crankcase bolt (M8) (Final)

2.6 19.0

Crankcase bolt (M6)

1.2 8.5

Oil pump mounting bolt

1.0

7.0

)

(Page 1D-64)

Oil pan bolt

1.0

7.0

)

(Page 1D-65)

Oil pressure switch

1.4

10.0

)

(Page 1D-66)

Gear position switch mounting bolt

6.5

0.65

4.7

)

(Page 1D-66)

Water pump mounting bolt

1.0

7.0

)

(Page 1D-67)

Cam chain tensioner bolt

2.3

16.5

)

(Page 1D-67)

Cam chain guide No. 1 bolt

2.3

16.5

)

(Page 1D-67)

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Engine Mechanical: 1D-87

NOTE

The specified tightening torque is described in the following.
“Throttle Cable Routing Diagram” (Page 1D-2)
“Throttle Body Components” (Page 1D-8)
“Throttle Body Construction” (Page 1D-9)
“Engine Assembly Installation” (Page 1D-24)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C
(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

B947H11408001

NOTE

Required service material is also described in the following.
“Throttle Body Components” (Page 1D-8)
“Engine Bottom Side Assembly” (Page 1D-56)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or
equivalent

P/No.: 99000–25010

Molybdenum oil

MOLYBDENUM OIL SOLUTION

—

Sealant

SUZUKI BOND No.1207B or
equivalent

P/No.: 99000–31140

Thread lock cement

THREAD LOCK CEMENT SUPER
“1322” or equivalent

P/No.: 99000–32110

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1D-88 Engine Mechanical:

Special Tool

B947H11408002

09900–20102

09900–20202

Vernier calipers (200 mm)

Micrometer (25 – 50 mm)

09900–20203

09900–20205

Micrometer (50 – 75 mm)

Micrometer (0 – 25 mm)

09900–20530

09900–20602

Cylinder gauge set

Dial gauge

09900–20605

09900–20607

Dial calipers (10 – 34 mm)

Dial gauge

09900–20701

09900–20803

Dial gauge chuck

Thickness gauge

09900–21304

09900–22301

V blocks

Plastigage (0.025 – 0.076
mm)

09900–22302

09900–22401

Plastigage (0.051 – 0.152
mm)

Small bore gauge (10 – 18
mm)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Engine Mechanical: 1D-89

09900–22403

09915–40610

Small bore gauge (18 – 35
mm)

Oil filter wrench

09915–63311

09915–64512

Compression gauge
attachment

Compression gauge

09916–10911

09916–14510

Valve lapper set

Valve lifter

09916–14522

09916–33210

Valve lifter attachment

Valve guide reamer (4.5
mm)

09916–33320

09916–34542

Valve guide reamer (9.8
mm)

Reamer handle

09916–43211

09916–53380

Valve guide installer &
remover

Valve guide installer
attachment

09916–77310

09916–84511

Piston ring compressor

Tweezer

09919–28620

09930–11950

Sleeve protector

Torx wrench (5 mm)

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Suzuki GSX-R1000. Service Manual - part 20