Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Conrod and crankshaft inspection

Refer to “engine bottom side disassembly” (page 1d- 49).

Refer to “engine bottom side assembly” .

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)

Suzuki GSX-R. Conrod small end i.D.


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)

Suzuki GSX-R. Conrod big end side clearance


  1. 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” . 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)

Suzuki GSX-R. Conrod big end side clearance


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)

Suzuki GSX-R. Crankshaft runout


Conrod crank pin bearing removal and installation
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Removal Remove the conrod crank pin bearings (1). Note  do not remove the beari ...

Conrod crank pin bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If ...

Other materials:

Air cleaner
The air cleaner element must be kept clean to provide good engine power and g1as mileage. If you use your motorcycle under normal low-stress conditions, you should service the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the ...

Rear brake master cylinder parts inspection
Refer to “rear brake master cylinder disassembly and assembly” . Master cylinder Inspect the master cylinder bore for any scratches or other damage. Piston / rubber parts Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust boot ...

Cam chain guide / cam chain tensioner removal and installation
Removal Remove the cylinder head cover. Refer to “engine top side disassembly” .  Remove the cam chain guide no. 2 (1). Remove the cylinder head. Refer to “engine top side disassembly”  and “engine bottom side disassembly” .  Remove the starter clutch. Refer to “s ...

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