Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Transmission removal

  1. Remove the engine assembly from the frame. Refer to engine assembly removal in section 1d .
  2.  Remove the engine top side. Refer to engine top side disassembly in section 1d .
  3.  Separate the upper and lower crankcases. Refer to engine bottom side disassembly in section 1d .

Countershaft assembly

  1. Remove the gearshift shaft plug (1) and gearshift fork/gearshift shaft (2).
  2.  Remove the clutch push rod oil seal (3) and countershaft assembly (4).

Suzuki GSX-R. Countershaft assembly


  1. Remove the bearing pin (5) and c-ring (6).

Suzuki GSX-R. Countershaft assembly


Gearshift fork and gearshift cam

  1. Remove the gearshift cam bearing retainer screws.
  2.  Remove the gearshift fork shaft (1).
  3.  Remove the gearshift cam (2) along with its bearing.
  4.  Remove the gearshift forks (3).

Suzuki GSX-R. Gearshift fork and gearshift cam


Driveshaft assembly

  1. Remove the spacer (1).
  2. Remove the driveshaft oil seal retainer (2).

Suzuki GSX-R. Driveshaft assembly


  1. Remove the driveshaft left bearing case bolts.

Suzuki GSX-R. Driveshaft assembly


  1. Using suitable size bolts (3), remove the driveshaft left bearing case (4).
  2.  Remove the dowel pin.

Suzuki GSX-R. Driveshaft assembly


  1. Remove the driveshaft right bearing case bolts.
  2.  Using suitable size bolts (5), remove the driveshaft right bearing assembly (6).

Suzuki GSX-R. Driveshaft assembly


  1. Remove the driveshaft assembly (7).

Suzuki GSX-R. Driveshaft assembly


Bearing and oil seal

Note

if there is no abnormal condition, the oil seal and bearing removal is not necessary.

 

Caution

the removed oil seal and bearing must be replaced with a new one.

  1. Remove the gearshift cam bearing (1) with the special tools.
Caution

be careful not to lean the bearing remover.

Special tool (a): 0992374511 (bearing remover)
(b): 0993030104 (rotor remover
sliding shaft)

Suzuki GSX-R. Bearing and oil seal


  1. Remove the gearshift shaft oil seal (2). (Lh only)

Suzuki GSX-R. Bearing and oil seal


  1. Remove the gearshift shaft bearings (3) and (4) with the special tool.

Special tool (c): 0992120240 (bearing remover
set)

Suzuki GSX-R. Bearing and oil seal


  1. Remove the driveshaft left bearing with the special tool.

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

Suzuki GSX-R. Bearing and oil seal


  1. Remove the driveshaft left bearing oil seal from the retainer using the special tool.

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

Suzuki GSX-R. Bearing and oil seal


Transmission components
2Nd drive gear 6Th drive gear 3Rd/4th drive gear 5Th drive gear Countershaft/1st drive gear Driveshaft 2Nd driven gear 6Th driven gear 3Rd driven ge ...

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 ...

Other materials:

Precautions
Precautions for clutch system Refer to general precautions in section 00 (page 00-1). Schematic and routing diagram Clutch cable routing diagram Refer to throttle cable routing diagram in section 1d . Diagnostic information and procedures Clutch system symptom diagnosis ...

Turn signal / side-stand relay removal and installation
Removal Remove the frame cover. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Remove the turn signal/side-stand relay (1). Installation Install the turn signal/side-stand relay in the reverse order of removal. ...

Rear brake hose removal and installation
Removal Drain brake fluid. Refer to brake fluid replacement .  Remove the rear brake hoses as shown in the rear brake hose routing diagram. Refer to rear brake hose routing diagram . Installation Caution the seal washers should be replaced with new ones to prevent ...

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