Toyota RAV4 manuals

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:

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

Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Driveshaft

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)

Suzuki GSX-R. Driveshaft


  1. Thrust
  2. Sharp edge

Driveshaft

Suzuki GSX-R. Driveshaft


Suzuki GSX-R. Driveshaft


Countershaft

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

Suzuki GSX-R. Countershaft


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:

DTC “c40” (p0505 / p0506 / p0507): isc valve circuit malfunction
Detected condition and possible cause Detected condition Possible cause C40/P0505 The circuit voltage of motor drive is unusual. Isc valve circuit open or shorted to ground. Air passage clogged.  Isc valve is fixed.  Isc valve prese ...

Gearshift shaft / gearshift cam plate removal and installation
Removal Remove the engine sprocket cover. Refer to “engine sprocket removal and installation” in section 3a .  Remove the clutch components. Refer to “clutch removal” in section 5c .  Remove the snap ring (1) and washer (2) from the gearshift shaft. Special tool : 09900–06 ...

The sport of motorcycling
Your motorcycle and this owner's manual have been designed by people like you who enjoy motorcycling. People become motorcyclists for many reasons. For starters, street riding is fun and invigorating. But no matter why you became a motorcyclist, or how experienced you are, you will eventu ...

© 2011-2026 Copyright www.suzukigsxr.org