Suzuki GSX-R 1000 Service Manual: 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 any, replace them with a specified set of bearings.
- 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))
- Tighten the conrod cap bolts to the specified torque, in two stages.
Note
|
Tightening torque conrod cap bolt: 37 n·m (3.7 Kgf-m, 26.5 Ib-ft) then turn in 1/6 (60°) turn
- 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)
Selection
- Check the corresponding conrod i.D. Code numbers ([1] or [2]) “a”.
Conrod i.D. Specification
- Check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) “b”.
- 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
Special tool
(a): 09900–20202 (micrometer (25 –
50
mm))
- Select the specified bearings from the bearing selection table.
| Caution the bearings should be replaced as a set. |
Bearing selection table
Bearing thickness specification
|
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:
Brake pad
Front
Rear
Inspect the front and rear brake
pads to see if they are worn down
to the grooved wear limit line 1. If
a pad is worn to the grooved wear
limit line, it must be replaced with
a new one. After replacing either
the front or rear brake pads, the
brake lever or pedal must be
...
Warning / caution / note
Please read this manual and follow its instructions
carefully. To emphasize special information, the symbol
and the words warning, caution and note have
special meanings. Pay special attention to the messages
highlighted by these signal words.
Indicates a
potential hazard that could ...
Clutch lever position switch inspection
Inspect the clutch lever position switch in the following
procedures:
disconnect the clutch lever position switch lead
wires (1).
Inspect the clutch lever position switch for continuity
with the tester.
If any abnormality is found, replace the switch with a
new one.
S ...