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:

Rear suspension components
Rear shock absorber Rear shock absorber mounting nut Cushion rod Cushion rod mounting nut Cushion lever Cushion lever mounting nut Swingarm pivot lock-nut Swingarm pivot shaft Swingarm pivot nut Swingarm Chain case Plate Chain adjus ...

Front fork disassembly and assembly
Refer to “front fork removal and installation” (page 2b- 2). Note the right and left front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side. Disassembly Turn the spring pre-load adjuster (1) t ...

Specifications
Service data Drive train unit: mm (in) except ratio Tightening torque specifications Note the specified tightening torque is described in the following. “Drive chain related components” Reference: for the tightening torque of fastener not specified in this section ...