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:
Camshaft inspection
Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Camshaft identification
The exhaust camshaft has the embossed letters “ex”
and the intake camshaft has the embossed letters “in”.
Cam wear
Check the camshaft for wear or damage.
Measure the cam height “a” w ...
Steering damper maintenance
Keep the steering damper
shaft 1 clean at all times.
Wipe off any oil residue with a
cloth.
Do not confuse the grease-like
residue on the steering damper's
shaft with an oil leak. Collection of
this residue is normal and is from
oil seal lubricant used in the
damper.
Yo ...
Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:
remove the fuel mesh filter. Refer to “fuel pump disassembly and
assembly” .
If the fuel mesh filter is clogged with foreign particles,
it hinders smooth gasoline flow resulting in loss of
engine power. Such a filter ...