Suzuki GSX-R 1000 Service Manual: 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.
If the conrod small end inside diameter exceeds the service limit, replace the conrod.
Special tool
(a): 09900–20602 (dial gauge)
(b): 09900–22401 (small bore gauge
(10 – 18
mm))
Conrod small end i.D.
Service limit: 15.040 Mm (0.5921 In)
Conrod big end side clearance
- Check the conrod big end side clearance using the thickness gauge.
Special tool
(a): 09900–20803 (thickness gauge)
Conrod big end side clearance service limit: 0.30 Mm (0.012 In)
- If the clearance exceeds the limit, remove the conrod and measure the conrod big end width and crank pin width. Refer to “engine bottom side assembly” . If any of the measurements are out of specification, replace the conrod or crankshaft.
Special tool
(b): 09900–20205 (micrometer (0 –
25 mm))
(c): 09900–20605 (dial calipers (10
– 34
mm))
Conrod big end width standard: 19.95 – 20.00 Mm (0.7854 – 0.7874 In)
Crank pin width standard: 20.10 – 20.15 Mm (0.7913 – 0.7933 In)
Crankshaft runout
Support the crankshaft using v-blocks as shown, with the two end journals resting on the blocks. Set up the dial gauge as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout exceeds the service limit.
Special tool
(a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (v blocks)
Crankshaft runout service limit: 0.05 Mm (0.002 In)
Conrod crank pin bearing removal and
installation
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Removal
Remove the conrod crank pin bearings (1).
Note
do not remove the beari ...
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 ...
Other materials:
Pair system inspection
Pair hose
Lift and support the fuel tank with the prop stay.
Refer to “fuel tank removal and installation” in section 1g .
Remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Inspect the pair hoses for wear or damage. If it is worn or da ...
Charging system symptom diagnosis
Condition
Possible cause
Correction / reference item
Generator does not
charge
Open- or short-circuited lead wires, or
loose lead connections.
Repair, replace or connect properly.
Short-circuited, grounded or open
generator coil.
Replace
...
Tp sensor adjustment
Inspect the tp sensor setting position and adjust it if
necessary in the following procedures:
connect the special tool (mode select switch) to the dealer mode
coupler. Refer to “self-diagnostic procedures” in section 1a .
Special tool
: 09930–82720 (mode selection switch)
Warn ...