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)
Conrod big end side clearance
- 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)
- 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)
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)
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:
Gearshift linkage inspection
Refer to “gearshift shaft / gearshift cam plate removal and installation” .
Gearshift shaft
Check the gearshift shaft for bend or wear.
Check the return spring for damage or fatigue.
If any defects are found, replace the defective part(-s).
Gearshift shaft oil seal
Inspect the gearshif ...
Procedure for returning
to service
Clean the entire motorcycle.
Remove the oily rags from the
air cleaner intake and muffler
outlet.
Drain all the engine oil. Install
a new oil filter and fill the
engine with fresh oil as outlined
in this manual.
Remove the spark plugs. Turn
the engine a few tim ...
Camshaft sprocket
Inspect the camshaft sprocket in the following
procedures:
remove the intake and exhaust camshafts. Refer to “engine top side
disassembly” .
Inspect the teeth of each camshaft sprocket for wear
or damage.
If they are worn or damaged, replace the sprocket/
camshaft assembl ...