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

Suzuki GSX-R 1000 Service Manual / Transmission / transaxle / Manual transmission / Repair instructions / 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 : 0990006107 (snap ring remover
(open type))

  1. Remove the gearshift shaft assembly (3).

Suzuki GSX-R. Gearshift shaft construction


  1. Remove the following parts from the gearshift shaft.

Special tool : 0990006107 (snap ring remover
(open type))

Suzuki GSX-R. Gearshift shaft construction


  1. Washer
  2. Snap ring
  3. Gearshift shaft return spring
  4. Gearshift cam drive plate
  5. Gearshift plate return spring
  6. Washer
  7. Gearshift shaft end screw
  1. Remove the gearshift cam plate bolt (11) and gearshift cam plate (12).
  2.  Remove the gearshift cam stopper (13).
  3.  Remove the gearshift arm stopper (14).

Suzuki GSX-R. Gearshift shaft construction


Installation

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

Caution

the removed snap rings must be replaced with new ones.

: Thread lock cement
9900032030 (thread lock cement super 1303 or equivalent)

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

Suzuki GSX-R. Gearshift shaft construction


Note

hook the return spring end a to the stopper.

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

Suzuki GSX-R. Gearshift shaft construction


Suzuki GSX-R. Gearshift shaft construction


Note

align the gearshift cam pin b with the gearshift cam plate hole c.

Suzuki GSX-R. Gearshift shaft construction


: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

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

Suzuki GSX-R. Gearshift shaft construction


: Thread lock cement
9900032110 (thread lock cement super 1322 or equivalent)

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

Suzuki GSX-R. Gearshift shaft construction


Suzuki GSX-R. Gearshift shaft construction


Note

pinch the gearshift arm stopper (8) with return spring ends e.

Suzuki GSX-R. Gearshift shaft construction


Special tool : 0990006107 (snap ring remover
(open type))


Gearshift shaft construction
Gearshift shaft Washer Snap ring Gearshift shaft return spring Gearshift cam drive plate Gearshift plate return spring 8.5 Nm (0.85 Kgf-m, 6.0 Lb ...

Gearshift linkage inspection
Refer to gearshift shaft / gearshift cam plate removal and installation . Gearshift shaft Check the gearshift shaft for bend or wear. Check the return spring for damage or fatigue. If any de ...

Other materials:

Handlebar components
Throttle grip Grip rubber Right handlebar switch box Left handlebar switch box Right handlebar Left handlebar Handlebar expander Handlebar balancer Apply handle grip bond. 23 Nm (2.3 Kgf-m, 16.5 Lbf-ft) 5.5 Nm (0.55 Kgf-m, 4.0 L ...

Front fork removal and installation
Note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal Remove the front wheel. Refer to front wheel assembly removal and installation in section 2d . ...

Warning / caution / note
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could ...

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