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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:

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

Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Driveshaft

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)

Suzuki GSX-R. Driveshaft


  1. Thrust
  2. Sharp edge

Driveshaft

Suzuki GSX-R. Driveshaft


Suzuki GSX-R. Driveshaft


Countershaft

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

Suzuki GSX-R. Countershaft


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:

Self-diagnostic procedures
Use of mode select switch Note  do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Such disconnection may erase memorized information in ec ...

Instrument panel
The fuel indicator light 8,12,13 Lcd's and tachometer needle work as follows to confirm their function when the ignition switch is turned to the "on" position. The fuel indicator light 8,12 and 13 come on for 3 seconds.  All lcd segments display for 3 seconds. &nbs ...

If a collision is imminent, do something
Many riders fear locking up their brakes or haven't learned to swerve to avoid an accident. Many inexperienced riders (and too many seasoned riders) use only their rear brake in an emergency, resulting in unnecessary impacts in some cases and unnecessarily high impact speeds in other case ...

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