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:
Starter torque limiter inspection
Removal
Remove the clutch cover. Refer to “clutch removal” in section 5c .
Remove the washers (1), starter idle gear no. 1 (2)
And no. 2 (3).
Remove the starter idle gear no. 2 Bearing (4), shaft
(5) and washer (6).
Hold the starter clutch with the special tool an ...
Conclusion
Traffic, road and weather conditions
vary. Other motorists'
actions are unpredictable. Your
motorcycle's condition can
change. These factors can best
be dealt with by giving every ride
your full attention.
Circumstances beyond your control
could lead to an accident. You
need to prepare fo ...
Fuel pump disassembly and assembly
Disassembly
Remove the fuel tank. Refer to “fuel tank removal and installation” .
Remove the fuel pump assembly (1) by removing its
mounting bolts diagonally.
Spilled gasoline should be wipe off
immediately.
Keep away from fire or spark.
Work in a wel ...