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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)

Suzuki GSX-R. Gearshift fork to groove clearance


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)

Suzuki GSX-R. Gearshift fork groove width


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)

Suzuki GSX-R. Gearshift fork thickness


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.

Suzuki GSX-R. Gearshift cam


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” .

Suzuki GSX-R. Gearshift cam bearing


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” .

Suzuki GSX-R. Driveshaft bearing


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” .

Suzuki GSX-R. Driveshaft bearing


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” .

Suzuki GSX-R. Driveshaft oil seal


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:

Starter motor components
O-ring Housing end (inside) O-ring Starter motor case Armature Housing end (outside) 10 N·m (1.0 Kgf-m, 7.0 Lbf-ft) 4 N·m (0.4 Kgf-m, 3.0 Lbf-ft) 5 N·m (0.5 Kgf-m, 3.5 Lbf-ft) Apply grease to sliding surface Apply moly ...

Ignition switch inspection
Inspect the ignition switch in the following procedures:  remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d .  Disconnect the ignition switch lead wire coupler (1). Inspect the ignition switch for continuity with a tester. If ...

Body frame construction
Frame Seat rail Seat rail bolt Collar Engine mounting thrust adjuster Engine mounting thrust adjuster lock-nut Engine mounting pinch bolt 50 N·m (5.0 Kgf-m, 36.0 Lbf-ft) 23 N·m (2.3 Kgf-m, 16.5 Lbf-ft) 45 N·m (4.5 Kgf-m, 32. ...

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