Suzuki GSX-R 1000 Service Manual: Gearshift shaft / gearshift cam plate removal and installation
Removal
- Remove the engine sprocket cover. Refer to “engine sprocket removal and installation” in section 3a .
- Remove the clutch components. Refer to “clutch removal” in section 5c .
- Remove the snap ring (1) and washer (2) from the gearshift shaft.
Special tool
: 09900–06107 (snap ring remover
(open
type))
- Remove the gearshift shaft assembly (3).
- Remove the following parts from the gearshift shaft.
Special tool
: 09900–06107 (snap ring remover
(open
type))
|
- Remove the gearshift cam plate bolt (11) and gearshift cam plate (12).
- Remove the gearshift cam stopper (13).
- Remove the gearshift arm stopper (14).
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. |
- Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque.
: Thread lock cement
99000–32030
(thread lock cement super “1303” or
equivalent)
Tightening torque gearshift arm stopper (a): 19 n·m (1.9 Kgf-m, 13.5 Lbf-ft)
- Assemble the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4).
- Tighten the gearshift cam stopper bolt (2) to the specified torque.
| Note hook the return spring end “a” to the stopper. |
Tightening torque gearshift cam stopper bolt (b): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)
- Check the gearshift cam stopper moves smoothly.
- Locate the gearshift cam in the neutral position.
- Install the gearshift cam plate (5).
| Note align the gearshift cam pin “b” with the gearshift cam plate hole “c”. |
- Apply a small quantity of thread lock to the gearshift cam plate bolt and tighten it to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque gearshift cam plate bolt (c): 13 n·m (1.3 Kgf-m, 9.5 Lbf-ft)
- Apply a small quantity of thread lock to the gearshift shaft end screw and tighten it to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque gearshift shaft end screw (d): 8.5 N·m (0.85 Kgfm, 6.0 Lbf-ft)
- When installing the gearshift shaft return spring, position the stopper “d” of gearshift arm between the shaft return spring ends “e”.
- Install the washer (6) and gearshift shaft assembly (7).
| Note pinch the gearshift arm stopper (8) with return spring ends “e”. |
- Install a new snap ring (9).
Special tool
: 09900–06107 (snap ring remover
(open
type))
- After installing the gearshift lever, check the gearshift lever height. Refer to “gearshift lever height inspection and adjustment” .
Gearshift shaft construction
Gearshift shaft
Washer
Snap ring
Gearshift shaft return spring
Gearshift cam drive plate
Gearshift plate return spring
8.5 N·m (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:
Transmission installation
Install the transmission in the reverse order of removal.
Pay attention to the following points:
Bearing and oil seal
Caution
replace the removed bearings and oil seals
with new ones.
Install the driveshaft left bearing oil seal into the
retainer using the special tool.
...
Gearshift lever construction
Gearshift lever bracket
Gearshift lever shaft
Washer
Snap ring
Gearshift lever
Footrest top surface
65 – 75 Mm (2.6 – 3.0 In)
28 N·m (2.8 Kgf-m,
20.0 Lbf-ft)
40 N·m
(4.0 Kgf-m, 29.0 Lbf-ft)
Apply grease.
Grease.
...
Front brake master cylinder / brake lever disassembly and assembly
Refer to “front brake master cylinder assembly removal and installation” .
Disassembly
Remove the reservoir cap (1), plate (2), diaphragm
(3) and reservoir tank (4).
Remove the brake light switch (5) and brake lever
(6).
Remove the dust boot (7) and push rod (8).
...