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Suzuki GSX-R 1000 Service Manual: Camshaft inspection

Refer to engine top side disassembly .

Refer to engine top side assembly .

Camshaft identification

The exhaust camshaft has the embossed letters ex and the intake camshaft has the embossed letters in.

Suzuki GSX-R. Camshaft identification


Cam wear

Check the camshaft for wear or damage.

Measure the cam height a with a micrometer.

Replace a camshaft if the cams are worn to the service limit.

Special tool : 0990020202 (micrometer (25 50
mm))

Cam height a service limit (in.): 37.38 Mm (1.472 In) service limit (ex.): 36.58 Mm (1.440 In)

Suzuki GSX-R. Cam wear


Camshaft runout

Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.

Special tool (a): 0990020607 (dial gauge)
(b): 0990020701 (dial gauge chuck)
(c): 0990021304 (v blocks)


Camshaft runout (in. & Ex.) Service limit: 0.10 Mm (0.004 In)


Camshaft journal wear

Inspect the camshaft journal wear in the following procedures:

  1.  determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.
  2.  Use the plastigauge to read the clearance at the widest portion, which is specified as follows.

Special tool

(a):
0990022301 (plastigage (0.025 0.076 Mm))

(b):
0990022302 (plastigage (0.051 0.152 Mm))

Suzuki GSX-R. Camshaft journal wear


  1. Install each camshaft journal holder to its original position. Refer to engine top side assembly .
  2.  Tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.

    Refer to engine top side assembly .

Note

do not rotate the camshafts with the plastigauge in place.

Tightening torque camshaft journal holder bolt: 10 nm (1.0 Kgfm, 7.0 Lbf-ft)

Suzuki GSX-R. Camshaft journal wear


  1. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale.
  2.  This measurement should be taken at the widest part of the compressed plastigauge.

Camshaft journal oil clearance (in. & Ex.) Service limit: 0.150 Mm (0.0059 In)

Suzuki GSX-R. Camshaft journal wear


  1. If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification.

Special tool (c): 0990020602 (dial gauge)
(d): 0990022403 (small bore gauge
(18 35 mm)) (e): 0990020205 (micrometer (0 25
mm))

Camshaft journal holder i.D. (In. & Ex.) Standard: 24.012 24.025 Mm (0.9454 0.9459 In)

Camshaft journal o.D. (In. & Ex.) Standard: 23.959 23.980 Mm (0.9433 0.9441 In)

Suzuki GSX-R. Camshaft journal wear


Suzuki GSX-R. Camshaft journal wear


Cylinder head cover related parts inspection
Refer to engine top side disassembly . Refer to engine top side assembly . Refer to cylinder head cover disassembly and assembly . Cylinder head cover Clean and check the gasket grooves ...

Camshaft sprocket
Inspect the camshaft sprocket in the following procedures:  remove the intake and exhaust camshafts. Refer to engine top side disassembly .  Inspect the teeth of each camshaft sp ...

Other materials:

Oil cooler / oil cooler hose inspection and cleaning
Refer to exterior parts removal and installation in section 9d . Oil cooler hose inspection Inspect the oil cooler hoses for any damage and oil leakage. If any defects are found, replace the oil cooler hose with a new one. Oil cooler inspection Remove the oil cooler guard (1). ...

Crankcase emission control system description
The engine is equipped with a pcv system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the pcv (breather) hose, air cleaner and throttle body. ...

Drive chain
This motorcycle has a master link type drive chain. We recommend that you take your motorcycle to an authorized suzuki dealer if the drive chain needs replacing. The condition and adjustment of the drive chain should be checked each day before you ride. Always follow the guidelines for ins ...

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