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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:

Excv cable removal and installation
Removal Turn the ignition switch off.  Remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Connect the special tool (mo ...

Rear brake pedal adjustment
The rear brake pedal position must be properly adjusted at all times or the disk brake pads will bear against the disk causing damage to the pads and to the disk surface. Adjust the brake pedal posit~ on in the following manner: Loosen lock nut 1, and turn the push rod 2 to locate t ...

Specifications
Service data Fi sensors Tightening torque specifications Reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list” in section 0c . ...

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