Engine Bottom Side Disassembly - Suzuki GSF1250 Service Manual

Piston Ring Free End Gap and Piston Ring End Gap
Measure the piston ring free end gap using vernier
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Special tool
(A): 09900–20102 (Vernier calipers (1/20 mm,
200 mm))
Piston ring free end gap
Service limit: (1st): 7.2 mm (0.28 in)
Service limit: (2nd): 7.6 mm (0.30 in)
Special tool
(B): 09900–20803 (Thickness gauge)
Piston ring end gap
Service limit: (1st): 0.50 mm (0.020 in)
Service limit: (2nd): 0.50 mm (0.020 in)
Piston Pin and Pin Bore
Measure the piston pin bore inside diameter using the
small bore gauge. If either is out of specification or the
difference between these measurements surpass limits,
replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000 mm, 1
mm))
(B): 09900–22403 (Small bore gauge (18 – 35
mm))
Piston pin bore I.D.
Service limit: 18.030 mm (0.7098 in)
Measure the piston pin outside diameter at three
positions using the micrometer. If any of the
measurements are out of specification, replace the
piston pin.
Special tool
Piston pin O.D.
Service limit: 17.980 mm (0.7079 in)
(A)
I649G1140265-03

Engine Bottom Side Disassembly

(B)
1) Remove the engine assembly. Refer to "Engine
2) Remove the water hose bracket (1) and water hoses
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Engine Mechanical:
(B)
(C): 09900–20205 (Micrometer (0 – 25 mm))
NOTE
The crankcase must be separated to service
the crankshaft and conrod.
Assembly Removal (Page 1D-17)".
(2).
2
1D-53
(A)
I649G1140267-03
(C)
I649G1140268-03
B718H11406024
2
1
2
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