Suzuki GSX-R Motorcycle Forums Gixxer.com banner

Engine rebuild

15K views 12 replies 4 participants last post by  Chef1000  
#1 ·
A little background- Ive had my 03 1000 for several years. Ran great for a while, noticed that I was fouling plugs, went through many steps. After some years I started losing compression, I was at 200's now around 170. So I took the motor out and im replacing the piston rings, all gaskets, and I got the head ported and polished. My snag now is I can't seem to split the cases
to get to the rings, someone told me I don't need to remove the flywheel or the lower case to get off the upper case. In the manual it basically takes the entire motor apart which I don't see necessary. I'm 99% sure I have all the bolts out unless there is a secret one. Any advice is appreciated, thanks.
Image
 
#3 ·
The cylinder and the cases are 1 piece so yes you do have to split them apart to get them off to access the pistons. On Hayabusa's the cylinders are a separate piece that come off on their own.
 
#6 ·
I have a manual. The manual breaks the motor completely down bottom and top. My question is can I get the the piston rings without disassembling every single component of the engine both bottom And top? My question is not answered in the manual, that's why I'm asking the biggest gsxr forum.


Sent from Motorcycle.com Free App
 
#7 ·
You must pull the heads, the pull the bottom case to get to the connecting rod bottoms since the pistons come out the top and can not come out from the bottom.
I believe I already answered this question, did you double post?
You do not need to remove to "fly wheel" at the end of the crank that the magneto sits in neither do you really have to remove the starter gears but you have to get to the connecting rods. I believe the oil pan can stay on but the lower case from the middle of the flywheel down.
 
#11 ·
Well I don't want to pay someone when I can learn and do it myself for a fraction of the price. I don't see how I'm taking short cuts, I need to replace the piston rings and didn't see the need to taking the bottom end apart if I didn't have to. Now that someone pointed me in the right direction, ill take the whole motor apart, clean it, replace every gasket, and rebuild. I just need some guidance from people like you guys who have done this before.



Sent from Motorcycle.com Free App
 
#13 ·
Ok so I took a better approach and stopped listening to everyone's advice. Following the manual I disassembled the motor. Between alot of extra hours at work and having to save a little money to get a good compressor and impact wrench (which I desperately needed) I haven't had time to get to it. So this weekend I tackled it.

I got a great deal on a rebuild, ported and polished head. I just have to put my cams in and adjust. The cylinders are getting ball honed at my local machine shop and while I was there just decided to get my new rings installed and measured correctly, should be done today. So next I have to clean all my parts, and start the reassembly.



Sent from Motorcycle.com Free App