Suzuki GSX-R 1000 Service Manual: 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 the crankshaft onto the upper crank case.
- Install the plastigauge onto each crankshaft journal.
Special tool
(a): 09900–22301 (plastigage (0.025 –
0.076
Mm))
- Mate the lower crankcase with the upper crankcase.
- 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 n·m (1.8 Kgf-m, 13.0 Lbf-ft) then turn in 50°
- 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)
Selection
- Check the corresponding crankcase journal i.D.
Codes “a” ([a], [b] or [c]), which are stamped on the rear of the upper crankcase.
Crankcase journal i.D. Specification
- Check the corresponding crankshaft journal o.D.
Codes “b” ([a], [b] or [c]), which are stamped on the crankshaft.
- 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
Special tool
(a): 09900–20202 (micrometer (25 –
50
mm))
- Select the specified bearings from the bearing selection table
Bearing selection table
Bearing thickness specification
|
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 crankshaft’s right-side and left-side thrust
bearings inserted into the ...
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 ...
Radiator cap inspection
Inspect the radiator cap in the following procedures:
remove the radiator cap. Refer to “cooling circuit inspection” .
Attach the radiator cap (1) to the radiator tester (2)
as shown.
Slowly apply pressure to the radiator cap.
If the radiator cap does not hold the pre ...
Rear brake master cylinder disassembly and assembly
Refer to “rear brake master cylinder assembly removal and installation” .
Disassembly
Disconnect the reservoir hose (1).
Remove the lock-nut (2).
Remove the brake hose connector (3) and o-ring
(4).
Special tool
: 09900–06108 (snap ring remover
(close
type))
Pu ...