Suzuki 2005 GSF1200 - Engine Bottom Side Disassembly

1D-42 Engine Mechanical:
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 measurement is more than the
limits, replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000mm,
1mm))
(B): 09900–22403 (Small bore gauge (18-
35mm))
Piston pin bore I.D.
Service limit: 20.030 mm (0.7886 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
(C): 09900–20205 (Micrometer (0-25mm))
Piston pin O.D.
Service limit: 19.980 mm (0.7866 in)
Engine Bottom Side Disassembly
B649G11406005
NOTE
The crankcase must be separated to service
the crankshaft and conrod.
1) Remove the engine assembly. Refer to “Engine
Assembly Removal: ”.
2) Disassemble the engine top side. Refer to “Engine
Top Side Disassembly: ”.
Starter Motor
Remove the starter motor (1).
Generator
Remove the generator (1).
Oil Filter
Remove the oil filter (1) using the special tool.
Special tool
: 09915–40610 (Oil filter wrench)
(A)
(B)
I649G1140267-02
(C)
I649G1140268-02
1
I649G1140094-01
1
I649G1140095-02
1
I649G1140033-02