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Suzuki GSX-R 1000 Service Manual: Conrod crank pin bearing inspection and selection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Conrod crank pin bearing inspection and selection

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

Refer to “engine bottom side assembly” .

Inspection

  1. Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown in the figure.

Special tool (a): 09900–22301 (plastigage (0.025
– 0.076 Mm))

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Tighten the conrod cap bolts to the specified torque, in two stages.
Note

  •  when installing the conrod cap bolts to the crank pin, make sure that i.D code “a” on the conrod faces towards the intake side.
  •  Never rotate the crankshaft or conrod when a piece of plastigauge is installed.

Tightening torque conrod cap bolt: 37 n·m (3.7 Kgf-m, 26.5 Ib-ft) then turn in 1/6 (60°) turn

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Remove the conrod cap bolts and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge.

    If the oil clearance exceeds the service limit, select the specified bearings from the bearing selection table.

Special tool (a): 09900–22301 (plastigage (0.025
– 0.076 Mm))

Conrod big end oil clearance standard: 0.040 – 0.064 Mm (0.0016 – 0.0025 In)

Conrod big end oil clearance service limit: 0.080 Mm (0.0031 In)

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


Selection

  1. Check the corresponding conrod i.D. Code numbers ([1] or [2]) “a”.

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


Conrod i.D. Specification

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) “b”.

Suzuki GSX-R. Conrod i.D. Specification


  1. Measure the conrod crank pin o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft.

Crank pin o.D. Specification

Suzuki GSX-R. Crank pin o.D. Specification


Special tool (a): 09900–20202 (micrometer (25 –
50 mm))

Suzuki GSX-R. Crank pin o.D. Specification


  1. Select the specified bearings from the bearing selection table.
Caution

the bearings should be replaced as a set.

Bearing selection table

Suzuki GSX-R. Bearing selection table


Bearing thickness specification

Suzuki GSX-R. Bearing thickness specification



  1. Color code
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. ...

Crankshaft journal bearing inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection Inspect each upper and lower crankcase bearing for any damage. Set ...

Other materials:

Countershaft gear / driveshaft gear disassembly and assembly
Refer to “transmission removal”  and “transmission installation” . Disassembly Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Drive or driven) so that they can be reinstalled in their original positions. Counte ...

Break-in procedures
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depen ...

Generator inspection
Generator coil resistance Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Disconnect the generator coupler (1). Measure the resistance between the three lead wires. If the resistance is out of specified value, replace the ...

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