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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:

Cylinder head cover related parts inspection
Refer to engine top side disassembly . Refer to engine top side assembly . Refer to cylinder head cover disassembly and assembly . Cylinder head cover Clean and check the gasket grooves a and pair reed valve mating surfaces b of the cylinder head cover. If there is anything unu ...

Clamp
Clamp the wire harness at such positions as indicated in wiring harness routing diagram in section 9a .  Bend the clamp properly so that the wire harness is clamped securely.  In clamping the wire harness, use care not to allow it to hang down.  Do not use wire or an ...

Specifications
Service data Electrical unit: mm Tightening torque specifications Note the specified tightening torque is described in the following. Starter motor components Reference: for the tightening torque of fastener not specified in this section, refer to tightening to ...

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