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”.
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)
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:
- determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.
- 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))
- Install each camshaft journal holder to its original position. Refer to “engine top side assembly” .
- 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)
- Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale.
- 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)
- 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)
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:
Diagnostic information and procedures
Engine mechanical symptom diagnosis
Refer to “engine symptom diagnosis” in section 1a .
Compression pressure check
The compression pressure reading of a cylinder is a
good indicator of its internal condition.
The decision to overhaul the cylinder is often based on
the results of a compressio ...
Rear suspension inspection
Inspect rear suspension
every 12 000 km (7 500 miles, 24 months)
Inspect the rear shock absorber for oil leakage and
check that there is no play in the swingarm.
Replace any defective parts, if necessary. Refer to “rear shock absorber removal
and installation” in section 2c , “cushion lever ...
Ignition switch inspection
Inspect the ignition switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the ignition switch lead wire coupler (1).
Inspect the ignition switch for continuity with a tester.
If ...