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:

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))

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

   Refer to “engine top side assembly” .

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

5. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale.
6.  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)

7. 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)