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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:

Front brake pad replacement
Loosen the pad mounting pins (1).  Remove the brake caliper by removing the caliper mounting bolts (2).  Remove the pad mounting pins (1), brake pads and spring. Caution do not operate the brake lever while the pads are removed.   Note when ...

Regulator / rectifier removal and installation
Removal Turn the ignition switch off.  Remove the right side cowling. Refer to “exterior parts removal and installation” in section 9d .  Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9). Remove the evap system purge ...

Specifications
Service data Wheel unit: mm (in) Tire Tightening torque specifications Note the specified tightening torque is described in the following. “Front wheel components”  “front wheel assembly construction”  “rear wheel components”  “rear wheel assembly c ...

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