Suzuki GSX-R 1000 Service Manual: 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 .
- Separate the upper and lower crankcases. Refer to “engine bottom side
disassembly” in section 1d .
Countershaft assembly
- Remove the gearshift shaft plug (1) and gearshift
fork/gearshift shaft (2).
- Remove the clutch push rod oil seal (3) and
countershaft assembly (4).
- Remove the bearing pin (5) and c-ring (6).
Gearshift fork and gearshift cam
- Remove the gearshift cam bearing retainer screws.
- Remove the gearshift fork shaft (1).
- Remove the gearshift cam (2) along with its bearing.
- Remove the gearshift forks (3).
Driveshaft assembly
- Remove the spacer (1).
- Remove the driveshaft oil seal retainer (2).
- Remove the driveshaft left bearing case bolts.
- Using suitable size bolts (3), remove the driveshaft
left bearing case (4).
- Remove the dowel pin.
- Remove the driveshaft right bearing case bolts.
- Using suitable size bolts (5), remove the driveshaft
right bearing assembly (6).
- Remove the driveshaft assembly (7).
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. |
- Remove the gearshift cam bearing (1) with the
special tools.
Caution
be careful not to lean the bearing remover. |
Special tool
(a): 09923–74511 (bearing remover)
(b): 09930–30104 (rotor remover
sliding
shaft)
- Remove the gearshift shaft oil seal (2). (Lh only)
- Remove the gearshift shaft bearings (3) and (4) with
the special tool.
Special tool
(c): 09921–20240 (bearing remover
set)
- Remove the driveshaft left bearing with the special
tool.
Special tool
(d): 09913–70210 (bearing
installing set (10
– 75 Ô))
- Remove the driveshaft left bearing oil seal from the
retainer using the special tool.
Special tool
(d): 09913–70210 (bearing
installing set (10
– 75 Ô))
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 ...
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:
Fi system troubleshooting
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as
described by the customer. For this purpose,
use of such an inspection form such as following will facilitate collecting
information to the point required for proper
analysis and diagnosis.
...
Service data
Valve + guide
unit: mm (in
Camshaft + cylinder head
unit: mm (in
Cylinder + piston + piston ring
unit: mm (in)
Conrod + crankshaft
unit: mm (in)
Balancer
unit: mm (in)
Throttle body
...
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 ...