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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.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Note

the stamped mark side of the driveshaft left bearing faces outside.

Special tool

(a):
09913–70210 (bearing installing set (10 – 75Ôö))

Suzuki GSX-R. Bearing and oil seal


Note

the stamped mark side of the gearshift shaft bearing faces outside.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

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

Suzuki GSX-R. Bearing and oil seal


Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ô))

Suzuki GSX-R. Bearing and oil seal


Driveshaft assembly

: 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)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

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

Suzuki GSX-R. Driveshaft assembly


: 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)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

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

: 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)

Suzuki GSX-R. Driveshaft assembly


Caution

replace the o-ring with a new one.

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

Suzuki GSX-R. Driveshaft assembly


Gearshift cam and gearshift fork

Suzuki GSX-R. Gearshift cam and gearshift fork


Suzuki GSX-R. Gearshift cam and gearshift fork


: 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)

Suzuki GSX-R. Gearshift cam and gearshift fork


Countershaft

Suzuki GSX-R. Countershaft


Note

align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing.

Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


Suzuki GSX-R. Countershaft


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:

Rear brake caliper parts inspection
Refer to “rear brake caliper disassembly and assembly” . Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston Inspect the brake caliper piston surface for any s ...

Countershaft gear / driveshaft gear disassembly and assembly
Refer to “transmission removal”  and “transmission installation” . Disassembly Caution identify the position of each removed part. Organize the parts in their respective groups (i.E., Drive or driven) so that they can be reinstalled in their original positions. Counte ...

Rear brake pedal adjustment
The rear brake pedal position must be properly adjusted at all times or the disk brake pads will bear against the disk causing damage to the pads and to the disk surface. Adjust the brake pedal posit~ on in the following manner: Loosen lock nut 1, and turn the push rod 2 to locate t ...

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