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): 0990020602 (dial gauge)
(b): 0990022401 (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): 0990020803 (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): 0990020205 (micrometer (0
25 mm)) (c): 0990020605 (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): 0990020607 (dial gauge)
(b): 0990020701 (dial gauge chuck)
(c): 0990021304 (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:

Ckp sensor inspection
Refer to electrical components location in section 0a . Ckp sensor peak voltage Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9). Disconnect the ckp sensor coupler (1). Note be sure that all of the couplers are connect ...

Helmet holders
This motorcycle has helmet holders underneath the rear seat. Hook your helmet on the helmet holder and lock the seat. Warning Riding with a helmet fastened to the helmet holder can interfere with rider control. Never carry a helmet fastened to the helmet holder. Fix the ...

To sensor removal and installation
Removal Remove the ap sensor. Refer to ap sensor removal and installation .  Disconnect the coupler (1) and remove the to sensor (2). Installation Install the to sensor in the reverse order of removal. Pay attention to the following point:  when installing the to s ...

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