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Suzuki GSX-R 1000 Service Manual: Conrod crank pin bearing inspection and selection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Conrod crank pin bearing inspection and selection

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

Refer to engine bottom side assembly .

Inspection

  1. Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings.

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Place the plastigauge axially along the crank pin, avoiding the oil hole, as shown in the figure.

Special tool (a): 0990022301 (plastigage (0.025
0.076 Mm))

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Tighten the conrod cap bolts to the specified torque, in two stages.
Note

  •  when installing the conrod cap bolts to the crank pin, make sure that i.D code a on the conrod faces towards the intake side.
  •  Never rotate the crankshaft or conrod when a piece of plastigauge is installed.

Tightening torque conrod cap bolt: 37 nm (3.7 Kgf-m, 26.5 Ib-ft) then turn in 1/6 (60) turn

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. 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): 0990022301 (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)

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


Selection

  1. Check the corresponding conrod i.D. Code numbers ([1] or [2]) a.

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


Conrod i.D. Specification

Suzuki GSX-R. Conrod crank pin bearing inspection and selection


  1. Check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) b.

Suzuki GSX-R. Conrod i.D. Specification


  1. 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

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


Special tool (a): 0990020202 (micrometer (25
50 mm))

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


  1. Select the specified bearings from the bearing selection table.
Caution

the bearings should be replaced as a set.

Bearing selection table

Suzuki GSX-R. Bearing selection table


Bearing thickness specification

Suzuki GSX-R. Bearing thickness specification



  1. Color code
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:

Special tools and equipment
Recommended service material Note required service material is also described in the following. Throttle body components  engine bottom side assembly Special tool ...

Right handlebar
Engine stop switch 1 "" Position The ignition circuit is off. The engine cannot start or run. "" Position The ignition circuit is on and the engine can run. Front brake lever 2 Apply the front brake by squeezing the front brake lever towards the grip. The brake ligh ...

Batiery
The battery is located under the front seat. Remove the front seat by referring to the seat lock and helmet holders section. This battery is sealed type and requires no maintenance. Have your dealer check the battery's state of charge periodically. The standard charging rate is 1.2A x ...

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