Conrod - Suzuki DR-Z400S 2001 Service Manual

PISTON PIN AND PIN BORE
Measure the piston pin bore diameter using the small bore gauge.
If the diameter exceeds the service limit, replace the piston with
a new one.
09900-20602: Dial gauge (1/1000 mm)
09900-22403: Small bore gauge (18 – 35 mm)
Piston pin bore
Service Limit: 20.030 mm (0.7886 in)
Measure the piston pin outside diameter at three positions us-
ing the micrometer. If any measurement exceeds the service
limit, replace the piston pin with a new one.
09900-20205: Micrometer (0 – 25 mm)
Piston pin O.D.
Service Limit: 19.980 mm (0.7866 in)

CONROD

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 with a new one.
09900-20605: Dial calipers
Conrod small end I.D.
Service Limit: 20.040 mm (0.7890 in)
CONROD DEFLECTION AND BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be estimated by checking
the movement of the small end of the rod. This method can also
be used to check the extent of wear on the parts of the conrod's
big end.
09900-20701: Magnetic stand
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
Conrod deflection
Service Limit: 3.0 mm (0.12 in)
Push the big end of the conrod to one side and measure the
side clearance using a thickness gauge. If the clearance exceeds
the service limit, replace the crankshaft assembly with a new
one or bring the deflection and the side clearance within the
service limit by replacing the worn parts (conrod, big end bear-
ing, crank pin, etc.) with new ones.
09900-20803: Thickness gauge
Big end side clearance
Service Limit: 1.00 mm (0.039 in)
ENGINE 3-35