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Suzuki GSX-R 1000 Service Manual: Drive chain replacement

Use the special tool in the following procedures, to cut and rejoin the drive chain.

Note

when using the special tool, apply a small quantity of grease to the threaded parts of the special tool.

Special tool : 0992222711 (drive chain cutting
and joint tool set)

Suzuki GSX-R. Drive chain replacement


Drive chain cutting

  1. Set up the special tool as shown in the figure.

Suzuki GSX-R. Drive chain cutting


  1. Tool body
  2. Grip handle
  3. Pressure bolt [a]
  4. Pressure bolt [b]
  5. Bar
  6. Adjuster bolt (with through hole)
  7. Pin remover
  8. Chain holder (engraved mark 500) with reamer bolt m5 x 10

 

Note

the tip of pin remover (7) should be positioned inside a approximately 5 mm (0.2 In) from the end face of pressure bolt [a] (3) as shown in the figure.

Suzuki GSX-R. Drive chain cutting


  1. 5 Mm (0.2 In)
  1. Place the drive chain link being disjointed on the chain holder (8) of the tool.
  2.  Turn in both the adjuster bolt (6) and pressure bolt [a] (3) so that each of their end hole fits over the chain joint pin properly.
  3.  Tighten the pressure bolt [a] (3) with the bar.

Suzuki GSX-R. Drive chain cutting


  1. Turn in the pressure bolt [b] (4) with the bar (5) and force out the drive chain joint pin (9).
Caution

continue turning in the pressure bolt [b] (4) until the joint pin should been completely pushed out of the chain.

 

Note

after the joint pin (9) is removed, loosen the pressure bolt [b] (4) and then pressure bolt [a] (3).

  1. Remove the joint pin (9) of the other side of joint plate.
Caution

never reuse joint pins, o-rings and plates.

Suzuki GSX-R. Drive chain cutting


Suzuki GSX-R. Drive chain cutting


Drive chain connecting

Do not use joint
clip type of drive chain. The joint clip may have a chance to drop which may cause severe damage to motorcycle and severe injury.

Joint plate installation

  1. Set up the special tool as shown in the figure.

Suzuki GSX-R. Joint plate installation


  1. Tool body
  2. Grip handle
  3. Joint plate holder (engraved mark f50)
  4. Wedge holder & wedge pin
  5. Adjuster bolt (without hole)
  6. Pressure bolt [a]
  7. Bar
  1. Apply grease to the joint pins (8), o-rings (9) and plates (10).
Caution

replace the joint pins (8), o-rings (9) and plates (10) with new ones.

  1. Connect both ends of the drive chain with the joint pins (8) inserted from the wheel side a as installed on the motorcycle.

Joint set part number did: 27620 40f20

Suzuki GSX-R. Joint plate installation


  1. Apply grease on the recessed portion of the joint plate holder (3) and set the joint plate (10).
Note

when positioning the joint plate (10) on the tool, its stamp mark must face the joint plate holder (3) side.

  1. Set the drive chain on the tool as illustrated and turn in the adjuster bolt (5) to secure the wedge holder and wedge pin (4).

Suzuki GSX-R. Joint plate installation


  1. Turn in the pressure bolt [a] (6) and align two joint pins (8) properly with the respective holes of the joint plate (10).
  2. Turn in the pressure bolt [a] (6) further using the bar (7) to press the joint plate over the joint pins.

Suzuki GSX-R. Joint plate installation


  1. Continue pressing the joint plate until the distance between the two joint plates comes to the specification.

Joint plate distance specification a 20.7 21.0 Mm (0.81 0.83 In)

Caution

if pressing of the joint plate makes the dimension out of specification excessively, the work must be carried out again by using new joint parts.

Suzuki GSX-R. Joint plate installation


Joint pin staking

  1. Set up the special tool as shown in the figure.

Suzuki GSX-R. Joint pin staking


  1. Tool body
  2. Grip handle
  3. Pressure bolt [a]
  4. Adjuster bolt (without hole)
  5. Staking pin (stowed inside grip handle behind rubber cap)
  6. Bar

 

Note

before staking the joint pin, apply a small quantity of grease to the staking pin (5).

  1. Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [a] (3) with the bar until the pin end diameter becomes the specified dimension.
Caution

  •  after joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
  •  Should any abnormal condition be found, reassemble the chain link using the new joint parts.

Pin end diameter specification a did: 5.7 6.0 Mm (0.22 0.24 In)

Suzuki GSX-R. Joint pin staking


Suzuki GSX-R. Joint pin staking


  1. Adjust the drive chain slack, after connecting it.

    Refer to drive chain inspection and adjustment in section 0b .

Sprocket mounting drum dust seal / bearing removal and installation
Removal Remove the rear wheel assembly. Refer to rear wheel assembly removal and installation in section 2d .  Remove the rear sprocket mounting drum assembly (1). Refer to rear spr ...

Specifications
Service data Drive train unit: mm (in) except ratio Tightening torque specifications Note the specified tightening torque is described in the following. Drive chain related ...

Other materials:

Special tools and equipment
Recommended service material Note required service material is also described in the following. Lubrication points Special tool ...

Ignition switch removal and installation
Removal Remove the air cleaner box. Refer to air cleaner box removal and installation in section 1d .  Disconnect the ignition switch lead wire coupler (1).  Disconnect the immobilizer lead wire coupler (2). (For e-02, 19, 24, 51) Remove the harness clamp (3). ...

Precautions
Precautions for engine electrical device Refer to general precautions in section 00 (page 00-1) and precautions for electrical circuit service in section 00 (page 00-2). Component location Engine electrical components location Refer to electrical components location in section 0a . Dia ...

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