Suzuki GSX-R 1000 Service Manual: Transmission related parts inspection
Refer to “transmission removal” , “transmission installation” and “countershaft gear / driveshaft gear disassembly and assembly” .
Gearshift fork to groove clearance
| Note the clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. |
Using the thickness gauge, check the gearshift fork clearance in the groove of its gear.
If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
Special tool
(a): 09900–20803 (thickness gauge)
Gearshift fork to gearshift fork groove clearance standard: 0.1 – 0.3 Mm (0.004 – 0.012 In) service limit: 0.5 Mm (0.02 In)
Gearshift fork groove width
Measure the gearshift fork groove width using the vernier calipers.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Gearshift fork groove width standard: 5.0 – 5.1 Mm (0.197 – 0.201 In)
Gearshift fork thickness
Measure the gearshift fork thickness using the vernier calipers.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Gearshift fork thickness standard: 4.8 – 4.9 Mm (0.189 – 0.193 In)
Gearshift cam
Inspect the gearshift cam groove for abnormal wear and damage. If any defects are found, replace the gearshift cam with a new one.
Gearshift cam bearing
Inspect the gearshift cam bearings, left and right for abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual. Refer to “transmission removal” and “transmission installation” .
Driveshaft bearing
Inspect the driveshaft left bearing for abnormal noise and smooth rotation while it is in the case.
Replace the bearing if there is anything unusual. Refer to “transmission removal” and “transmission installation” .
Inspect the driveshaft right bearing for abnormal noise and smooth rotation.
If there is anything unusual, replace the bearing assembly. Refer to “transmission removal” and “transmission installation” .
Driveshaft oil seal
Inspect the driveshaft left bearing dust seal for wear and damage.
Replace the dust seal if there is anything unusual. Refer to “transmission removal” and “transmission installation” .
Gear position (gp) switch inspection
Refer to “side-stand / ignition interlock system parts inspection” in section 1i .
Countershaft gear / driveshaft gear
disassembly and assembly
Refer to “transmission removal” and “transmission installation” .
Disassembly
Caution
identify the position of each removed part.
Organize the parts in their respective groups
...
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 swi ...
Other materials:
Steering stem bearing removal and installation
Removal
Remove the steering stem upper bearing and steering stem lower bracket.
Refer to “steering / steering damper removal and installation” .
Remove the steering stem lower bearing inner race
using a chisel.
Remove the steering stem upper and lower bearing
races using ...
Exterior parts construction
Upper cowling bracket
: set the punch mark to the front and upper side.
Rear view mirror cushion
: set the dent side to inside.
To frame
To headlight assembly
To sprocket cove
To side-stand bracket
...
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 ...