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:
Gearshift lever
This motorcycle has a 6-speed
transmission which operates as
shown. To shift properly, squeeze
the clutch lever and close the
throttle at the same time you
operate the gearshift lever. Lift the
gearshift lever to upshift and
depress the lever to downshift.
Neutral is located between lo ...
Isc valve preset and opening initialization
When removing or replacing the isc valve, set the isc
valve to the following procedures:
turn the ignition switch on.
Set up the sds tool. (Refer to the sds operation
manual for further details.)
Click the “active control”.
Click the “isc learned value reset” (1) ...
Rear brake light switch inspection and adjustment
Check the rear brake light switch so that the brake light
will come on just before pressure is felt when the brake
pedal is depressed. If the brake light switch adjustment
is necessary, turn the adjuster nut (1) in or out while
holding the brake pedal.
Brake fluid level check
Refer to “bra ...