Toyota RAV4 manuals

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:

Starter relay inspection
Inspect the starter relay in the following procedures:  remove the starter relay. Refer to “starter relay removal and installation” .  Apply 12 v to “a” and “b” terminals and check for continuity between the positive and negative terminals using the multi-circuit tester. If th ...

Generator removal and installation
Removal Drain engine oil. Refer to “engine oil and filter replacement” in section 0b .  Remove the left side cowling. Refer to “exterior parts removal and installation” in section 9d .  Disconnect the generator coupler (1). Remove the generator cover (2). ...

Ignition switch removal and installation
Removal Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Disconnect the ignition switch lead wire coupler (1).  Disconnect the immobilizer lead wire coupler (2). (For e-02, 19, 24, 51) Remove the harness clamp (3). ...

© 2011-2017 Copyright www.suzukigsxr.org