Suzuki 1200 bandit, Service Manual

Page: 129 / 447

Engine Mechanical: 1D-61
Conrod and Crankshaft Inspection
B649G11406064
Refer to “Conrod Removal and Installation: ”.
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 (1/1000mm,
1mm))
(B): 09900–22403 (Small bore gauge (18-
35mm))
Conrod small end I.D.
Service limit: 20.040 mm (0.7890 in)
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: 0.3 mm (0.012 in)
2) If the clearance exceeds the limit, remove the conrod
and measure the conrod big end width and crank pin
width. Refer to “Conrod Removal and Installation: ”.
If any of the measurements are out of specification,
replace the conrod or crankshaft.
Special tool
(B): 09900–20205 (Micrometer (0-25mm))
(C): 09900–20605 (Dial calipers (1/100 mm,
10 - 34 mm))
Conrod big end width
Standard: 20.95 – 21.00 mm (0.825 – 0.827 in)
Crank pin width
Standard: 21.10 – 21.15 mm (0.831 – 0.833 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): 09900–20606 (Dial gauge (1/100 mm))
(B): 09900–20701 (Magnetic stand)
(C): 09900–21304 (V-block (100mm))
Crankshaft runout
Service limit: 0.05 mm (0.002 in)
(A)
(B)
I649G1140329-01
(A)
I649G1140330-01
(B)
(C)
I649G1140331-01
(C) (C)
(A)
(B)
I649G1140332-01