Suzuki GSX-R 1000 Service Manual: Countershaft gear / driveshaft gear disassembly and assembly

Suzuki GSX-R 1000 Service Manual / Transmission / transaxle / Manual transmission / Repair instructions / 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 (i.E., Drive or driven) so that they can be reinstalled in their original positions.

Countershaft

Disassemble the countershaft as shown in the transmission construction. Refer to “transmission construction” .

Pay attention to the following points:

remove the 6th drive gear snap ring (1) from its groove and slide it towards the 3rd/4th drive gears (2).

Special tool : 09900–06104 (snap ring remover
(open type))

Suzuki GSX-R. Countershaft

Slide the 6th (3) and 2nd (4) drive gears toward the 3rd/4th drive gears (2), then remove the 2nd drive gear circlip (5).
Remove the 2nd drive gear (4) and 6th drive gear (3).

Suzuki GSX-R. Countershaft

Remove the countershaft bearing (6) using hydraulic press.

Suzuki GSX-R. Countershaft

Driveshaft

Disassembly the driveshaft as shown in the transmission construction. Refer to “transmission construction” .

Assembly

Note

when reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. Refer to “transmission construction” .

Caution

never reuse a snap ring. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed.
When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
After installing a snap ring, make sure that it is completely seated in the groove and securely fitted.

Note

rotate the bearing by hand to inspect if there is any abnormal noise and for smooth rotation. Replace the bearing if there is anything unusual.
Before installing the gears, apply engine oil to the driveshaft and countershaft.
Before installing the oil seal, apply grease to the oil seal lip.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

When installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure.

Suzuki GSX-R. Driveshaft

Thrust
Sharp edge

Driveshaft

When installing the gear bushings onto the driveshaft, align the shaft oil holes “a” with the bushing oil hole “b”.

Suzuki GSX-R. Driveshaft

Countershaft

Install the countershaft bearing (1) using a hydraulic press and special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Countershaft

When installing the gear bushing onto the countershaft, align the shaft oil hole “a” with the bushing oil hole “b”.

Suzuki GSX-R. Countershaft

Transmission construction

Countershaft Driveshaft ...

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 clear ...

Other materials:

Engine components removable with the engine in place
Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of engine Item Removal Inspection Installation ...

Iat sensor removal and installation
Removal Remove the air cleaner box. Refer to “air cleaner box removal and installation” in section 1d . Remove the iat sensor (1) from the air cleaner box. Installation Install the iat sensor in the reverse order of removal. Pay attention to the following point: t ...

Brake fluid
Check the brake fluid level in both front and rear brake fluid reservoirs. If the level in either reservoir is below the lower mark, inspect for brake pad wear and leaks. Warning Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or ...