Conrod And Crankshaft Inspection; Conrod Small End I.d.; Conrod Big End Side Clearance; Crankshaft Runout - Suzuki GSX-R1000 Service Manual

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Conrod and Crankshaft Inspection

Refer to "Engine Bottom Side Disassembly" (Page 1D-
49).
Refer to "Engine Bottom Side Assembly" (Page 1D-56).

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)
(B)

Conrod Big End Side Clearance

1) 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)
(A)
email: info@motomatrix.co.uk / www.motomatrix.co.uk
B947H11406041
(A)
I823H1140280-01
I823H1140281-01
2) 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"
(Page 1D-56). 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)
(B)

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)
(A)
(C)
Engine Mechanical: 1D-77
(C)
I823H1140282-01
(C)
(B)
I947H1140235-01