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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): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Note

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

Special tool

(a):
09913–70210 (bearing installing set (10 – 75Ôö))

Suzuki GSX-R. Bearing and oil seal


Note

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

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Driveshaft assembly

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

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

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

Suzuki GSX-R. Driveshaft assembly


: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

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

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

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

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

: Grease 99000–25010 (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
99000–32110 (thread lock cement super “1322” or equivalent)

Tightening torque gearshift cam bearing retainer screw (a): 10 n·m ( 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:

Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:  remove the fuel mesh filter. Refer to “fuel pump disassembly and assembly” .  If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power. Such a filter ...

Valve clearance inspection and adjustment
Inspect valve clearance initially every 24 000 km (14 500 miles, 48 months) Inspection Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.  Lift an ...

Cooling fan relay inspection
Inspect the fan relay in the following procedures:  remove the frame covers. Refer to “exterior parts removal and installation” in section 9d (page 9d- 6).  Remove the cooling fan relay (1). First check the insulation between “a” and “b” terminals with tester. Then ap ...

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