Toyota RAV4 manuals

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:

Specifications
Service data Drive train unit: mm (in) except ratio Tightening torque specifications Note the specified tightening torque is described in the following. Transmission components  gearshift lever construction  gearshift shaft / gearshift cam plate componen ...

Starter torque limiter inspection
Removal Remove the clutch cover. Refer to clutch removal in section 5c .  Remove the washers (1), starter idle gear no. 1 (2) And no. 2 (3). Remove the starter idle gear no. 2 Bearing (4), shaft (5) and washer (6). Hold the starter clutch with the special tool an ...

Fuses
The main fuse is located under the front seat. To access the fuse, remove the seat by referring to the seat lock and helmet holders. The fuses are located inside the left fairing. One 1 oa and one 15a spare fuses are provided inside the fuse box. They are designed to open when ...

2011-2020 Copyright www.suzukigsxr.org