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Suzuki GSX-R 1000 Service Manual: Crankshaft journal bearing inspection and selection

Suzuki GSX-R 1000 Service Manual / Engine / Engine mechanical / Repair instructions / Crankshaft journal bearing inspection and selection

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

Refer to engine bottom side assembly .

Inspection

  1. Inspect each upper and lower crankcase bearing for any damage.

Suzuki GSX-R. Inspection


Suzuki GSX-R. Inspection


  1. Set the crankshaft onto the upper crank case.
  2.  Install the plastigauge onto each crankshaft journal.

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

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


  1. Mate the lower crankcase with the upper crankcase.
  2.  Tighten the crankshaft journal bolts (m9). Tighten each bolt a little at a time to equalize the pressure in the following two steps.
Note

do not rotate the crankshaft when a piece of plastigauge is installed.

Tightening torque crankshaft journal bolt (m9): 18 nm (1.8 Kgf-m, 13.0 Lbf-ft) then turn in 50

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


  1. Remove the lower crankcase and measure the width of 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.

Crankshaft journal oil clearance standard: 0.016 0.034 Mm (0.0006 0.0013 In)

Crankshaft journal oil clearance service limit: 0.080 Mm (0.0031 In)

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


Selection

  1. Check the corresponding crankcase journal i.D.

    Codes a ([a], [b] or [c]), which are stamped on the rear of the upper crankcase.

Suzuki GSX-R. Selection


Crankcase journal i.D. Specification

Suzuki GSX-R. Crankcase journal i.D. Specification


  1. Check the corresponding crankshaft journal o.D.

    Codes b ([a], [b] or [c]), which are stamped on the crankshaft.

Suzuki GSX-R. Crankcase journal i.D. Specification


  1. Measure the crankshaft o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft.

Crankshaft journal o.D. Specification

Suzuki GSX-R. Crankshaft journal o.D. Specification


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

Suzuki GSX-R. Crankshaft journal o.D. Specification


  1. Select the specified bearings from the bearing selection table

Bearing selection table

Suzuki GSX-R. Bearing selection table


Bearing thickness specification

Suzuki GSX-R. Bearing selection table


Suzuki GSX-R. Bearing selection table


  1. Color code
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 ...

Crankshaft thrust clearance inspection and selection
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Inspection With the crankshafts right-side and left-side thrust bearings inserted into the ...

Other materials:

Cam chain tension adjuster inspection
The cam chain tension adjuster is maintained to proper tension automatically.  Remove the cam chain tension adjuster. Refer to engine top side disassembly .  Holding the cam chain tension adjuster as shown in the figure, compress the plunger by turning the adjuster body unt ...

Fuel injector inspection and cleaning
Inspect the fuel injector in the following procedures:  remove the fuel injector. Refer to throttle body disassembly and assembly in section 1d .  Check the fuel injector for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lin ...

Transmission installation
Install the transmission in the reverse order of removal. Pay attention to the following points: Bearing and oil seal Caution replace the removed bearings and oil seals with new ones. Install the driveshaft left bearing oil seal into the retainer using the special tool. ...

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