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

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

2. 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))

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

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

4. 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

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

Conrod i.D. Specification

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

3. 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))

4. Select the specified bearings from the bearing selection table.

Bearing selection table

Bearing thickness specification