Suzuki GSX-R 1000 Service Manual: Countershaft gear / driveshaft gear disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Transmission / transaxle / Manual transmission / Repair instructions / Countershaft gear / driveshaft gear disassembly and assembly

Refer to “transmission removal” and “transmission installation” .

Disassembly

Caution

identify the position of each removed part.

Organize the parts in their respective groups (i.E., Drive or driven) so that they can be reinstalled in their original positions.

Countershaft

Disassemble the countershaft as shown in the transmission construction. Refer to “transmission construction” .

Pay attention to the following points:

remove the 6th drive gear snap ring (1) from its groove and slide it towards the 3rd/4th drive gears (2).

Special tool : 09900–06104 (snap ring remover
(open type))

Suzuki GSX-R. Countershaft

Slide the 6th (3) and 2nd (4) drive gears toward the 3rd/4th drive gears (2), then remove the 2nd drive gear circlip (5).
Remove the 2nd drive gear (4) and 6th drive gear (3).

Suzuki GSX-R. Countershaft

Remove the countershaft bearing (6) using hydraulic press.

Suzuki GSX-R. Countershaft

Driveshaft

Disassembly the driveshaft as shown in the transmission construction. Refer to “transmission construction” .

Assembly

Note

when reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. Refer to “transmission construction” .

Caution

never reuse a snap ring. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed.
When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
After installing a snap ring, make sure that it is completely seated in the groove and securely fitted.

Note

rotate the bearing by hand to inspect if there is any abnormal noise and for smooth rotation. Replace the bearing if there is anything unusual.
Before installing the gears, apply engine oil to the driveshaft and countershaft.
Before installing the oil seal, apply grease to the oil seal lip.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure.

Suzuki GSX-R. Driveshaft

Thrust
Sharp edge

Driveshaft

When installing the gear bushings onto the driveshaft, align the shaft oil holes “a” with the bushing oil hole “b”.

Suzuki GSX-R. Driveshaft

Countershaft

Install the countershaft bearing (1) using a hydraulic press and special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Countershaft

When installing the gear bushing onto the countershaft, align the shaft oil hole “a” with the bushing oil hole “b”.

Suzuki GSX-R. Countershaft

Transmission construction

Countershaft Driveshaft ...

Transmission related parts inspection

Refer to “transmission removal” , “transmission installation” and “countershaft gear / driveshaft gear disassembly and assembly” . Gearshift fork to groove clearance Note the clear ...

Other materials:

Schematic and routing diagram
Cooling circuit diagram Water hose routing diagram Thermostat air bleeder hole Cushion O-ring Radiator heat guard : be careful not to damage the pawls when removing. Yellow marking White marking Clamp end should face downward ...

Steering damper maintenance
Keep the steering damper shaft 1 clean at all times. Wipe off any oil residue with a cloth. Do not confuse the grease-like residue on the steering damper's shaft with an oil leak. Collection of this residue is normal and is from oil seal lubricant used in the damper. Yo ...

Radiator / cooling fan motor removal and installation
Removal Remove the inner under cowlings. Refer to “exterior parts removal and installation” in section 9d . Drain engine coolant. Refer to “cooling system inspection” in section 0b . Disconnect the reservoir tank inlet hose (1) and water air bleed hose (2). Remove ...