Suzuki GSX-R 1000 Service Manual: Gearshift shaft / gearshift cam plate removal and installation

Removal

1. Remove the engine sprocket cover. Refer to “engine sprocket removal and installation” in section 3a .
2.  Remove the clutch components. Refer to “clutch removal” in section 5c .
3.  Remove the snap ring (1) and washer (2) from the gearshift shaft.

Special tool : 09900–06107 (snap ring remover
(open type))

4. Remove the gearshift shaft assembly (3).

5. Remove the following parts from the gearshift shaft.

Special tool : 09900–06107 (snap ring remover
(open type))

6. Remove the gearshift cam plate bolt (11) and gearshift cam plate (12).
7.  Remove the gearshift cam stopper (13).
8.  Remove the gearshift arm stopper (14).

Installation

Install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to the following points:

• Apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque.

: Thread lock cement
99000–32030 (thread lock cement super “1303” or equivalent)

Tightening torque gearshift arm stopper (a): 19 n·m (1.9 Kgf-m, 13.5 Lbf-ft)

• Assemble the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4).
• Tighten the gearshift cam stopper bolt (2) to the specified torque.

Tightening torque gearshift cam stopper bolt (b): 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)

• Check the gearshift cam stopper moves smoothly.
•  Locate the gearshift cam in the neutral position.
•  Install the gearshift cam plate (5).

• Apply a small quantity of thread lock to the gearshift cam plate bolt and tighten it to the specified torque.

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

Tightening torque gearshift cam plate bolt (c): 13 n·m (1.3 Kgf-m, 9.5 Lbf-ft)

• Apply a small quantity of thread lock to the gearshift shaft end screw and tighten it to the specified torque.

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

Tightening torque gearshift shaft end screw (d): 8.5 N·m (0.85 Kgfm, 6.0 Lbf-ft)

• When installing the gearshift shaft return spring, position the stopper “d” of gearshift arm between the shaft return spring ends “e”.

• Install the washer (6) and gearshift shaft assembly (7).

• Install a new snap ring (9).

Special tool : 09900–06107 (snap ring remover
(open type))

• After installing the gearshift lever, check the gearshift lever height. Refer to “gearshift lever height inspection and adjustment” .