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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:

Special tools and equipment
Recommended service material Note required service material is also described in the following. “Transmission components”  “gearshift lever construction”  “gearshift shaft / gearshift cam plate components”  “gearshift shaft construction” Special to ...

Exterior parts removal and installation
Side frame cover Removal Note the left and right side frame covers are installed symmetrically and therefore the removal/installation procedure for one side is the same as that for the other side. Remove the bolt (1).  Remove the side frame cover (2). ...

Cam chain tensioner inspection
Inspect the cam chain tensioner in the following procedures:  remove the cam chain tensioner. Refer to “cam chain guide / cam chain tensioner removal and installation” .  Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new ...

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