Suzuki GSX-R 1000 Service Manual: Transmission installation
Install the transmission in the reverse order of removal.
Pay attention to the following points:
Bearing and oil seal
| Caution replace the removed bearings and oil seals with new ones. |
- Install the driveshaft left bearing oil seal into the retainer using the special tool.
Special tool
(a): 09913–70210 (bearing
installing set (10
– 75 Ô))
- Install the driveshaft left bearing with the special tool.
| Note the stamped mark side of the driveshaft left bearing faces outside. |
Special tool
(a):
09913–70210 (bearing installing set (10
– 75Ôö))
- Install the gearshift shaft bearings (1) and (2) with the special tool.
| Note the stamped mark side of the gearshift shaft bearing faces outside. |
Special tool
(a): 09913–70210 (bearing
installing set (10
– 75 Ô))
- Install the gearshift shaft oil seal (3) with the special tool.
Special tool
(a): 09913–70210 (bearing
installing set (10
– 75 Ô))
- Apply grease to the oil seal lip.
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Install the gearshift cam bearing with the special tool.
Special tool
(a): 09913–70210 (bearing
installing set (10
– 75 Ô))
Driveshaft assembly
- Put the driveshaft assembly (1) into the lower crankcase.
- Install the driveshaft right bearing assembly (2).
- Apply thread lock to the bolts and tighten them to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque driveshaft right bearing case bolt (a): 12 n·m (1.2 Kgf-m, 8.7 Lbf-ft)
- Install the dowel pin.
- Apply grease to the o-ring and install the driveshaft left bearing case (3).
| Caution replace the o-ring with a new one. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Apply thread lock to the bolts and tighten them to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque driveshaft left bearing case bolt (b): 12 n·m (1.2 Kgf-m, 8.7 Lbf-ft)
- Apply grease to the oil seal lip and o-ring.
| Caution replace the o-ring with a new one. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Install the oil seal retainer (4).
- Apply thread lock to the screws and tighten them to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque driveshaft oil seal retainer screw (c): 12 n·m (1.2 Kgf-m, 8.7 Lbf-ft)
- Apply grease to the o-ring (5) and install it to the driveshaft.
| Caution replace the o-ring with a new one. |
: Grease 99000–25010 (suzuki
super
grease “a” or equivalent)
- Install the spacer (6).
Gearshift cam and gearshift fork
- Install the gearshift forks (1) as shown.
- Install the gearshift cam (2) with the bearing fitted.
- With engaging each fork end to the cam groove, insert the fork shaft (3).
- Apply thread lock to the screws and tighten them to the specified torque.
: Thread lock cement
99000–32110
(thread lock cement super “1322” or
equivalent)
Tightening torque gearshift cam bearing retainer screw (a): 10 n·m ( 1.0 Kgf-m, 7.0 Lbf-ft)
Countershaft
- Install the c-ring (1) and bearing pin (2) to the upper crankcase.
- Install the countershaft assembly to the upper crankcase.
| Note align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing. |
- Turn the bearing and set the bearing dowel pin in position.
- Install the clutch push rod oil seal (3).
- Install the gearshift fork/gearshift shaft (4) and gearshift shaft plug (5).
Transmission removal
Remove the engine assembly from the frame. Refer to “engine assembly
removal” in section 1d .
Remove the engine top side. Refer to “engine top side disassembly” in
section 1d .
&nbs ...
Transmission construction
Countershaft
Driveshaft
...
Other materials:
Ecm removal and installation
Removal
Remove the frame covers. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Disconnect the battery (–) lead wire.
Remove the tool set (1) and prop stay (2).
Disconnect the hose clamp (3) (e-33 only) and
starter relay (4).
Remo ...
Crankshaft thrust clearance inspection and
selection
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Inspection
With the crankshaft’s right-side and left-side thrust
bearings inserted into the upper crankcase.
Measure the thrust clearance “a” between the leftside
thrust bearing and ...
Tightening torque list
Engine
Fi system + intake air system
Cooling system
Chassis
Tightening torque chart
For other bolts and nuts not listed in the preceding page, refer to this
chart:
Conventional bolt
“4” Marked bolt
“7” Marked bolt
...