Suzuki GSX-R 1000 Service Manual: Engine sprocket removal and installation

Removal

1. Remove the gearshift link arm (1) from the gearshift shaft.

2. Remove the speed sensor (2).
3. Remove the engine sprocket cover (3).

4. Support the motorcycle with a jack or wooden block.
5.  Loosen the rear axle nut (4) and left and right chain adjuster lock-nuts (5).
6.  Loosen the chain adjusters (6) to provide additional chain slack.

7. Remove the speed sensor rotor (7) by removing its bolt while depressing the rear brake pedal.

8. Remove the engine sprocket nut (8) while depressing the rear brake pedal.

9. Remove the washer (9).
10.  Remove the engine sprocket (10).

Installation

Install the engine sprocket in the reverse order of removal. Pay attention to the following points:

•  apply thread lock to the driveshaft.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent)

• Tighten the engine sprocket nut (1) to the specified torque.

Tightening torque engine sprocket nut (a): 145 n·m (14.5 Kgf-m, 105.0 Lbf-ft)

• Tighten the speed sensor rotor bolt (2) to the specified torque.

Tightening torque speed sensor rotor bolt (b): 28 n·m (2.8 Kgf-m, 20.0 Lbf-ft)

• Before installing the engine sprocket cover, apply a small quantity of grease to the clutch push rod.

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

• Install the engine sprocket cover (3).
• Tighten the speed sensor mounting bolt (4) to the specified torque.

Tightening torque speed sensor mounting bolt (c): 6.5 N·m (0.65 Kgf-m, 4.5 Lbf-ft)

• Fit the gearshift link arm to the gearshift shaft so that the gearshift lever is located at height “a” below the footrest.

Gearshift lever height “a” standard: 65 – 75 mm (2.6 – 3.0 In)

• Adjust the drive chain slack. Refer to “drive chain inspection and adjustment” in section 0b (page 0b- 14).