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:

Inspection after cleaning
For extended life of your motorcycle, lubricate according to "general lubrication" section . Warning Wet brakes can cause poor braking performance and may lead to an accident. Avoid a possible accident by expecting longer stopping distances after washing your ...

Crankshaft journal bearing inspection and selection
Refer to engine bottom side disassembly (page 1d- 49). Refer to engine bottom side assembly . Inspection Inspect each upper and lower crankcase bearing for any damage. Set the crankshaft onto the upper crank case.  Install the plastigauge onto each crankshaft jour ...

Regulated voltage inspection
Inspect the regulated voltage in the following procedures:  remove the front seat. Refer to exterior parts removal and installation in section 9d (page 9d- 6).  Start the engine and keep it running at 5 000 r/min with the dimmer switch turned hi position. Measure the dc vo ...

2011-2019 Copyright www.suzukigsxr.org