Toyota RAV4 manuals

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 : 09900–20202 (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): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (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):
09900–22301 (plastigage (0.025 – 0.076 Mm))

(b):
09900–22302 (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 n·m (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): 09900–20602 (dial gauge)
(d): 09900–22403 (small bore gauge
(18 – 35 mm)) (e): 09900–20205 (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:

Cushion rod inspection
Refer to “cushion rod removal and installation” . Collar and spacer Remove the collar and spacer from the cushion rod.  Inspect the collar and spacer for any flaws or other damage. If any defects are found, replace it with a new one. Cushion rod bearing Insert the collar a ...

Rear brake master cylinder assembly removal and installation
Refer to “rear brake hose routing diagram” (page 4a- 2). Removal Remove the right side frame cover. Refer to “exterior parts removal and installation” in section 9d .  Remove the rear brake fluid reservoir mounting bolt (1). Drain brake fluid. Refer to “brake fluid replac ...

Cooling system inspection
Inspect cooling system every 6 000 km (4 000 miles, 6 months) Replace engine coolant every 2 years Engine coolant level inspection Hold the motorcycle vertically.  Check the engine coolant level by observing the “f” and “l” lines on the engine coolant reservoir tank. If the level i ...

© 2011-2017 Copyright www.suzukigsxr.org