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Suzuki GSX-R 1000 Service Manual: Crankshaft journal bearing inspection and selection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Crankshaft journal bearing inspection and selection

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

Refer to “engine bottom side assembly” .

Inspection

  1. Inspect each upper and lower crankcase bearing for any damage.

Suzuki GSX-R. Inspection


Suzuki GSX-R. Inspection


  1. Set the crankshaft onto the upper crank case.
  2.  Install the plastigauge onto each crankshaft journal.

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

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


  1. Mate the lower crankcase with the upper crankcase.
  2.  Tighten the crankshaft journal bolts (m9). Tighten each bolt a little at a time to equalize the pressure in the following two steps.
Note

do not rotate the crankshaft when a piece of plastigauge is installed.

Tightening torque crankshaft journal bolt (m9): 18 n·m (1.8 Kgf-m, 13.0 Lbf-ft) then turn in 50°

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


  1. Remove the lower crankcase and measure the width of 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.

Crankshaft journal oil clearance standard: 0.016 – 0.034 Mm (0.0006 – 0.0013 In)

Crankshaft journal oil clearance service limit: 0.080 Mm (0.0031 In)

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


Selection

  1. Check the corresponding crankcase journal i.D.

    Codes “a” ([a], [b] or [c]), which are stamped on the rear of the upper crankcase.

Suzuki GSX-R. Selection


Crankcase journal i.D. Specification

Suzuki GSX-R. Crankcase journal i.D. Specification


  1. Check the corresponding crankshaft journal o.D.

    Codes “b” ([a], [b] or [c]), which are stamped on the crankshaft.

Suzuki GSX-R. Crankcase journal i.D. Specification


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

Crankshaft journal o.D. Specification

Suzuki GSX-R. Crankshaft journal o.D. Specification


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

Suzuki GSX-R. Crankshaft journal o.D. Specification


  1. Select the specified bearings from the bearing selection table

Bearing selection table

Suzuki GSX-R. Bearing selection table


Bearing thickness specification

Suzuki GSX-R. Bearing selection table


Suzuki GSX-R. Bearing selection table


  1. Color code
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 ...

Crankshaft thrust clearance inspection and selection
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Inspection With the crankshaft’s right-side and left-side thrust bearings inserted into the ...

Other materials:

Fuel injector inspection and cleaning
Inspect the fuel injector in the following procedures:  remove the fuel injector. Refer to “throttle body disassembly and assembly” in section 1d .  Check the fuel injector for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lin ...

Water pump disassembly and assembly
Refer to “water pump removal and installation” . Disassembly Remove the air bleeder bolt (1) if necessary. Remove the water pump case screws. Remove the o-ring (2). Hold the impeller (3) with water pump pliers and remove the impeller securing bolt (4). Remove t ...

Precautions
Precautions for driveline / axle Refer to “general precautions” in section 00 (page 00-1). Never inspect or adjust the drive chain while the engine is running.   Caution  do not use trichloroethylene, gasoline or such similar solvent. These fluids will d ...

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