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:
Oil pressure switch inspection
Inspect the oil pressure switch in the following
procedures:
Note
before inspecting the oil pressure switch, check if the engine oil level
is correct. Refer to “engine oil and filter replacement” in section 0b .
Remove the left side cowling. Refer to “exterior parts removal ...
Starter motor components
O-ring
Housing end (inside)
O-ring
Starter motor case
Armature
Housing end (outside)
10
N·m (1.0 Kgf-m, 7.0 Lbf-ft)
4 N·m (0.4
Kgf-m, 3.0 Lbf-ft)
5 N·m (0.5
Kgf-m, 3.5 Lbf-ft)
Apply grease to sliding
surface
Apply moly ...
Diagnostic information and procedures
Starting system symptom diagnosis
Condition
Possible cause
Correction / reference item
Engine does not turn
though the starter motor
runs
Faulty starter clutch.
Replace.
Starter button is not
effective
Run down battery
Repair or replac ...