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Suzuki GSX-R 1000 Service Manual: 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.

Special tool (a): 0991370210 (bearing
installing set (10 75 ))

Suzuki GSX-R. Bearing and oil seal


Note

the stamped mark side of the driveshaft left bearing faces outside.

Special tool

(a):
0991370210 (bearing installing set (10 75ö))

Suzuki GSX-R. Bearing and oil seal


Note

the stamped mark side of the gearshift shaft bearing faces outside.

Special tool (a): 0991370210 (bearing
installing set (10 75 ))

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 0991370210 (bearing
installing set (10 75 ))

: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 0991370210 (bearing
installing set (10 75 ))

Suzuki GSX-R. Bearing and oil seal


Driveshaft assembly

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

Tightening torque driveshaft right bearing case bolt (a): 12 nm (1.2 Kgf-m, 8.7 Lbf-ft)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Driveshaft assembly


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

Tightening torque driveshaft left bearing case bolt (b): 12 nm (1.2 Kgf-m, 8.7 Lbf-ft)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 9900025010 (suzuki
super grease a or equivalent)

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

Tightening torque driveshaft oil seal retainer screw (c): 12 nm (1.2 Kgf-m, 8.7 Lbf-ft)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 9900025010 (suzuki
super grease a or equivalent)

Suzuki GSX-R. Driveshaft assembly


Gearshift cam and gearshift fork

Suzuki GSX-R. Gearshift cam and gearshift fork


Suzuki GSX-R. Gearshift cam and gearshift fork


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

Tightening torque gearshift cam bearing retainer screw (a): 10 nm ( 1.0 Kgf-m, 7.0 Lbf-ft)

Suzuki GSX-R. Gearshift cam and gearshift fork


Countershaft

Suzuki GSX-R. Countershaft


Note

align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing.

Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Transmission removal
Remove the engine assembly from the frame. Refer to engine assembly removal in section 1d .  Remove the engine top side. Refer to engine top side disassembly in section 1d . &nbs ...

Transmission construction
Countershaft Driveshaft ...

Other materials:

Steering components
Steering stem head nut Steering stem upper bracket Steering stem lock-nut Washer Steering stem nut Dust seal cover Dust seal Steering stem upper bearing Steering stem lower bearing Lower seal Steering stem lower bracket Steering stem lo ...

Gear position (gp) switch removal and installation
Removal Turn the ignition switch off.  Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).  Disconnect the gear position switch lead wire coupler (1). Remove the engine sprocket cover. Refer to engine sprocket r ...

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 defects are found, replace the defective part(-s). Gearshift shaft oil seal Inspect the gearshif ...

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