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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 : 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:

Starter motor disassembly and assembly
Refer to “starter motor removal and installation” . Disassembly Disassemble the starter motor as shown in the starter motor components diagram. Refer to “starter motor components” . Assembly Reassemble the starter motor in the reverse order of removal. Pay attention to the following points: ...

Ignition coil and spark plug removal and installation
Removal The hot engine can burn you. Wait until the engine is cool enough to touch. Turn the ignition switch off.  Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Disconnect the lead wire couplers (1). ...

Side-stand / ignition interlock system parts inspection
Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-stand switch Turn the ignition switch off.  Remove the left si ...

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