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:
Exhaust control valve inspection
Inspect exhaust control valve
initially at 1 000 km (600 miles, 2 months) and every
12 000 km (7 500 miles, 24 months) thereafter
Inspect exhaust control valve as follows:
remove the left side cowling. Refer to “exterior parts removal and
installation” in section 9d .
Check t ...
Ignition switch inspection
Inspect the ignition switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the ignition switch lead wire coupler (1).
Inspect the ignition switch for continuity with a tester.
If ...
Gearshift lever height inspection and
adjustment
Inspect and adjust the gearshift lever height in the
following procedures:
inspect the gearshift lever height “a” between the
lever top and footrest.
Adjust the gearshift lever height if necessary.
Gearshift lever height “a”
standard: 65 – 75 mm (2.6 – 3.0 In)
Loosen the l ...