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Suzuki GSX-R 1000 Service Manual: Gearshift shaft / gearshift cam plate removal and installation

Suzuki GSX-R 1000 Service Manual / Transmission / transaxle / Manual transmission / Repair instructions / Gearshift shaft / gearshift cam plate removal and installation

Removal

  1. Remove the engine sprocket cover. Refer to engine sprocket removal and installation in section 3a .
  2.  Remove the clutch components. Refer to clutch removal in section 5c .
  3.  Remove the snap ring (1) and washer (2) from the gearshift shaft.

Special tool : 0990006107 (snap ring remover
(open type))

  1. Remove the gearshift shaft assembly (3).

Suzuki GSX-R. Gearshift shaft construction


  1. Remove the following parts from the gearshift shaft.

Special tool : 0990006107 (snap ring remover
(open type))

Suzuki GSX-R. Gearshift shaft construction


  1. Washer
  2. Snap ring
  3. Gearshift shaft return spring
  4. Gearshift cam drive plate
  5. Gearshift plate return spring
  6. Washer
  7. Gearshift shaft end screw
  1. Remove the gearshift cam plate bolt (11) and gearshift cam plate (12).
  2.  Remove the gearshift cam stopper (13).
  3.  Remove the gearshift arm stopper (14).

Suzuki GSX-R. Gearshift shaft construction


Installation

Install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to the following points:

Caution

the removed snap rings must be replaced with new ones.

: Thread lock cement
9900032030 (thread lock cement super 1303 or equivalent)

Tightening torque gearshift arm stopper (a): 19 nm (1.9 Kgf-m, 13.5 Lbf-ft)

Suzuki GSX-R. Gearshift shaft construction


Note

hook the return spring end a to the stopper.

Tightening torque gearshift cam stopper bolt (b): 10 nm (1.0 Kgfm, 7.0 Lbf-ft)

Suzuki GSX-R. Gearshift shaft construction


Suzuki GSX-R. Gearshift shaft construction


Note

align the gearshift cam pin b with the gearshift cam plate hole c.

Suzuki GSX-R. Gearshift shaft construction


: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

Tightening torque gearshift cam plate bolt (c): 13 nm (1.3 Kgf-m, 9.5 Lbf-ft)

Suzuki GSX-R. Gearshift shaft construction


: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

Tightening torque gearshift shaft end screw (d): 8.5 Nm (0.85 Kgfm, 6.0 Lbf-ft)

Suzuki GSX-R. Gearshift shaft construction


Suzuki GSX-R. Gearshift shaft construction


Note

pinch the gearshift arm stopper (8) with return spring ends e.

Suzuki GSX-R. Gearshift shaft construction


Special tool : 0990006107 (snap ring remover
(open type))


Gearshift shaft construction
Gearshift shaft Washer Snap ring Gearshift shaft return spring Gearshift cam drive plate Gearshift plate return spring 8.5 Nm (0.85 Kgf-m, 6.0 Lb ...

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 de ...

Other materials:

Ignition system check
Remove the spark plugs and reattach them to the spark plug caps. Put the engine stop switch in the "" position and ignition switch in the "on" position. While holding a spark plug with its base firmly against the engine, push the electric starter butt ...

Starting the engine
Before attempting to start the engine, make sure:  The transmission is in neutral.  The engine stop switch is in the "" position. Note: this motorcycle has a starter interlock system for the ignition and starter circuit. The engine can only be started if:   ...

Balancer shaft disassembly and assembly
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Disassembly Remove the balancer shaft. Refer to engine bottom side disassembly .  Remove the washers, balancer gear and dampers from the shaft. Assembly Assembly is in the re ...

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