Suzuki GSX-R 1000 Service Manual: Drive chain replacement

Suzuki GSX-R 1000 Service Manual / Driveline / axle / Drive chain / drive train / drive shaft / Repair instructions / 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 : 09922–22711 (drive chain cutting
and joint tool set)

Suzuki GSX-R. Drive chain replacement

Drive chain cutting

Set up the special tool as shown in the figure.

Suzuki GSX-R. Drive chain cutting

Tool body
Grip handle
Pressure bolt [a]
Pressure bolt [b]
Bar
Adjuster bolt (with through hole)
Pin remover
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

5 Mm (0.2 In)

Place the drive chain link being disjointed on the chain holder (8) of the tool.
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.
Tighten the pressure bolt [a] (3) with the bar.

Suzuki GSX-R. Drive chain cutting

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).

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

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

Set up the special tool as shown in the figure.

Suzuki GSX-R. Joint plate installation

Tool body
Grip handle
Joint plate holder (engraved mark “f50”)
Wedge holder & wedge pin
Adjuster bolt (without hole)
Pressure bolt [a]
Bar

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.

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

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.

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

Turn in the pressure bolt [a] (6) and align two joint pins (8) properly with the respective holes of the joint plate (10).
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

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

Set up the special tool as shown in the figure.

Suzuki GSX-R. Joint pin staking

Tool body
Grip handle
Pressure bolt [a]
Adjuster bolt (without hole)
Staking pin (stowed inside grip handle behind rubber cap)
Bar

Note

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

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

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:

Gearshift linkage inspection
Refer to “gearshift shaft / gearshift cam plate removal and installation” . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...

Precautions
Precautions for driveline / axle Refer to “general precautions” in section 00 (page 00-1). Never inspect or adjust the drive chain while the engine is running. Caution do not use trichloroethylene, gasoline or such similar solvent. These fluids will d ...

Regulated voltage inspection
Inspect the regulated voltage in the following procedures: remove the front seat. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6). Start the engine and keep it running at 5 000 r/min with the dimmer switch turned hi position. Measure the dc vo ...