Toyota RAV4 manuals

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): 0990022301 (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 nm (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): 0990022301 (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): 0990020202 (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:

Front brake caliper parts inspection
Refer to front brake caliper disassembly and assembly . Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the surface of brake caliper pistons for a ...

Rear wheel assembly construction
Rear sprocket nut Rear axle nut Brake disc bolt Clearance 60 Nm (6.0 Kgf-m, 43.0 Lbf-ft) 100 Nm (10 kgf-m, 72.5 Lbf-ft) 35 Nm (3.5 Kgf-m, 25.5 Lbf-ft) Apply grease. Apply thread lock to the thread part. ...

Battery visual inspection
Inspect the battery in the following procedures:  remove the front seat. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of th ...

2011-2017 Copyright www.suzukigsxr.org