Suzuki GSX-R1000. Service Manual - part 35

5B-18 Manual Transmission: 

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:

CAUTION

!

 

The removed snap rings must be replaced 
with new ones.

 

• 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.

NOTE

Hook the return spring end “A” to the 
stopper.

 

Tightening torque
Gearshift cam stopper bolt (b):  10 N·m (1.0 kgf-
m, 7.0 lbf-ft)

4. Washer

5. Snap ring

6. Gearshift shaft return spring

7. Gearshift cam drive plate

8. Gearshift plate return spring

9. Washer

10. Gearshift shaft end screw

5

6

7

8

9

10

4

I947H1520004-01

11

12

13

14

I947H1520005-02

(a)

I947H1520006-02

1

2

3

4

I947H1520007-01

(b)

2

“A”

I947H1520008-01

Manual Transmission:  5B-19

• Check the gearshift cam stopper moves smoothly.

• Locate the gearshift cam in the neutral position.

• Install the gearshift cam plate (5).

NOTE

Align the gearshift cam pin “B” with the 
gearshift cam plate hole “C”.

 

• 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 kgf-
m, 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).

NOTE

Pinch the gearshift arm stopper (8) with 
return spring ends “E”.

 

5

“C”

“B”

I947H1520009-01

(c)

I947H1520010-01

(d)

I947H1520011-01

“D”

“E”

I947H1520012-01

6

7

8

“E”

I947H1520013-01

5B-20 Manual Transmission: 

• 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” (Page 5B-16).

Gearshift Linkage Inspection

B947H15206015

Refer to “Gearshift Shaft / Gearshift Cam Plate Removal 
and Installation” (Page 5B-17).

Gearshift Shaft

Check the gearshift shaft for bend or wear.
Check the return spring for damage or fatigue.
If any defects are found, replace the defective part(-s).

Gearshift Shaft Oil Seal

Inspect the gearshift shaft oil seal lip for damage or 
wear. If any defect is found, replace the oil seal with a 
new one.

Gearshift Shaft Bearing

Inspect the gearshift shaft bearings for abnormal noise 
and smooth rotation. Replace the bearing if there is 
anything unusual.

Gearshift Shaft Oil Seal / Bearing Removal and 
Installation

B947H15206016

Removal

1) Remove the gearshift shaft. Refer to “Gearshift Shaft 

/ Gearshift Cam Plate Removal and Installation” 
(Page 5B-17).

2) Remove the gearshift shaft oil seal (1).

3) Remove the bearings (2) and (3) with the special 

tools.

Special tool

(A):  09921–20210 (Bearing remover (12 

mm))

(B):  09930–30104 (Rotor remover sliding 

shaft)

9

I947H1520014-01

I947H1520015-01

I947H1520016-02

I947H1520017-01

1

I947H1520018-01

(A)

(A)

(B)

(B)

2

3

I947H1520019-01

Manual Transmission:  5B-21

Installation

Install the oil seal and bearing in the reverse order of 
removal. Pay attention to the following points:

CAUTION

!

 

The removed oil seal and bearings must be 
replaced with new ones.

 

• Install the bearings with the special tool.

NOTE

The stamped mark side of gearshift shaft 
bearing faces outside.

 

Special tool

(A):  09913–70210 (Bearing installing set (10 

– 75 

Φ

))

• Install the oil seal with the special tool.

Special tool

(A):  09913–70210 (Bearing installing set (10 

– 75 

Φ

))

• Apply grease to the oil seal lip.

:  Grease 99000–25010 (SUZUKI SUPER 

GREASE “A” or equivalent)

Specifications

Service Data

B947H15207001

Drive Train

Unit: mm (in) Except ratio

(A)

(A)

I947H1520020-01

(A)

I947H1520021-01

I947H1520022-01

Item

Standard

Limit

Primary reduction ratio

1.617 (76/47)

—

Final reduction ratio

2.470 (42/17)

—

Gear ratios

Low

2.562 (41/16)

—

2nd

2.052 (39/19)

—

3rd

1.714 (36/21)

—

4th

1.500 (36/24)

—

5th

1.360 (34/25)

—

Top

1.269 (33/26)

—

Gearshift fork to groove clearance

0.1 – 0.3 (0.004 – 0.012)

0.5 (0.02)

Gearshift fork groove width

5.0 – 5.1 (0.197 – 0.201)

—

Gearshift fork thickness

4.8 – 4.9 (0.189 – 0.193)

—

Gearshift lever height

65 – 75 (2.6 – 3.0)

—

5B-22 Manual Transmission: 

Tightening Torque Specifications

B947H15207002

NOTE

The specified tightening torque is described in the following.
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-15)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-16)
“Gearshift Shaft Construction” (Page 5B-17)

 

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C 
(Page 0C-9).

Special Tools and Equipment

Recommended Service Material

B947H15208001

NOTE

Required service material is also described in the following.
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-15)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-16)
“Gearshift Shaft Construction” (Page 5B-17)

 

Fastening part

Tightening torque

Note

N

⋅

m

kgf-m

lbf-ft

Driveshaft right bearing case bolt

12

1.2 

8.7 

)

(Page 5B-6)

Driveshaft left bearing case bolt

12

1.2 

8.7 

)

(Page 5B-7)

Driveshaft oil seal retainer screw

12

1.2 

8.7 

)

(Page 5B-7)

Gearshift cam bearing retainer screw

10

1.0 

7.0 

)

(Page 5B-8)

Gear position switch mounting bolt

6.5

0.65 

4.5 

)

(Page 5B-14)

Gearshift arm stopper

19

1.9 

13.5 

)

(Page 5B-18)

Gearshift cam stopper bolt

10

1.0 

7.0 

)

(Page 5B-18)

Gearshift cam plate bolt

13

1.3 

9.5 

)

(Page 5B-19)

Gearshift shaft end screw

8.5

0.85 

6.0 

)

(Page 5B-19)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI SUPER GREASE “A” or 
equivalent

P/No.: 99000–25010

)

(Page 5B-6) / 

)

(Page 5B-

7) / 

)

(Page 5B-7) / 

)

(Page 5B-7) / 

)

(Page 5B-

11) / 

)

(Page 5B-14) / 

)

(Page 5B-21)

Thread lock cement

THREAD LOCK CEMENT SUPER 
“1303” or equivalent

P/No.: 99000–32030

)

(Page 5B-18)

THREAD LOCK CEMENT SUPER 
“1322” or equivalent

P/No.: 99000–32110

)

(Page 5B-6) / 

)

(Page 5B-

7) / 

)

(Page 5B-7) / 

)

(Page 5B-8) / 

)

(Page 5B-

19) / 

)

(Page 5B-19)

Manual Transmission:  5B-23

Special Tool

B947H15208002

09900–06104

09900–06107

Snap ring remover (Open 
type)

Snap ring remover (Open 
type)

)

(Page 5B-10)

)

(Page 5B-17) / 

)

(Page 5B-18) / 

)

(Page 5B-20)

09900–20102

09900–20803

Vernier calipers (200 mm)

Thickness gauge

)

(Page 5B-12) / 

)

(Page 5B-12)

)

(Page 5B-12)

09913–70210

09921–20210

Bearing installing set (10 – 
75 

Φ

)

Bearing remover (12 mm)

)

(Page 5B-5) / 

)

(Page 5B-

5) / 

)

(Page 5B-5) / 

)

(Page 5B-5) / 

)

(Page 5B-

6) / 

)

(Page 5B-6) / 

)

(Page 5B-6) / 

)

(Page 5B-

11) / 

)

(Page 5B-21) / 

)

(Page 5B-21)

)

(Page 5B-20)

09921–20240

09923–74511

Bearing remover set

Bearing remover

)

(Page 5B-5)

)

(Page 5B-4)

09930–30104
Rotor remover sliding shaft

)

(Page 5B-4) / 

)

(Page 5B-

20)

5C-1 Clutch: 

Transmission / Transaxle

Clutch

Precautions

Precautions for Clutch System

B947H15300001

Refer to “General Precautions” in Section 00 (Page 00-1).

Schematic and Routing Diagram

Clutch Cable Routing Diagram

B947H15302001

Refer to “Throttle Cable Routing Diagram” in Section 1D (Page 1D-2).

Diagnostic Information and Procedures

Clutch System Symptom Diagnosis

B947H15304001

Condition

Possible cause

Correction / Reference Item

Engine is noisy (Noise 
seems to come from the 
clutch)

Worn countershaft spline.

Replace countershaft.

Worn clutch hub spline.

Replace clutch hub.

Worn clutch plate teeth.

Replace clutch plate.

Distorted clutch plate.

Replace.

Worn clutch release bearing.

Replace.

Weakened clutch damper.

Replace primary driven gear.

Clutch slips

Weakened clutch spring.

Replace.

Worn or distorted clutch pressure plate.

Replace.

Distorted clutch plate.

Replace.

Clutch: 5C-2

Repair Instructions

Clutch Lever Position Switch Inspection

B947H15306001

Inspect the clutch lever position switch in the following 
procedures:

1) Disconnect the clutch lever position switch lead 

wires (1).

2) Inspect the clutch lever position switch for continuity 

with the tester.
If any abnormality is found, replace the switch with a 
new one.

Special tool

:  09900–25008 (Multi circuit tester set)

Tester knob indication
Continuity (

)

Clutch lever position switch

3) Connect the clutch lever position switch lead wires.

Clutch Cable Inspection

B947H15306002

Refer to “Clutch Cable Play Inspection and Adjustment” 
in Section 0B (Page 0B-14).

Clutch Cable Removal and Installation

B947H15306003

Removal

1) Remove the left side cowling. Refer to “Exterior 

Parts Removal and Installation” in Section 9D 
(Page 9D-6).

2) Disconnect the clutch cable from the clutch lever. 

Refer to “Handlebar Removal and Installation” in 
Section 6B (Page 6B-2).

3) Remove the clutch cable as shown in the throttle 

cable routing diagram. Refer to “Throttle Cable 
Routing Diagram” in Section 1D (Page 1D-2).

Installation

1) Install the clutch cable as shown in the throttle cable 

routing diagram. Refer to “Throttle Cable Routing 
Diagram” in Section 1D (Page 1D-2).

2) Reinstall the removed parts.

1

I947H1530001-02

Terminal (B/Y)

Terminal (B/W)

FREE

Color

Position

I649G1530004-03

5C-3 Clutch: 

Clutch Control System Components

B947H15306004

1

2

3

4

(a)

(b)

(c)

I947H1530043-02

1. Push rod

4. Clutch cable

: 10 N

⋅

m (1.0 kgf-m, 0.7 lbf-ft)

2. Clutch release camshaft

: 1 N

⋅

m (0.1 kgf-m, 0.7 lbf-ft)

: Apply grease.

3. Clutch release arm

: 6 N

⋅

m (0.6 kgf-m, 4.5 lbf-ft)

: Do not reuse.

Clutch: 5C-4

Clutch Components

B947H15306005

1

2

3

11

10

12

13

14

15

16

4/5

3

3

5

3

5

3

5

3

5

3

5

3

6

7

8

9

4/5

(a)

(b)

FWD

FWD

I947H1530044-03

1. Clutch pressure plate

8. Spring washer

15. Primary driven gear assembly

2. Clutch push piece

9. Spring washer seat

16. Push rod

3. No. 1 drive plate (8 pcs.)

10. Clutch sleeve hub

: 10 N

⋅

m (1.0 kgf-m, 7.0 lbf-ft)

4. No. 3 driven plate (0 – 2 pcs.)

11. Seat washer

: 95 N

⋅

m (9.5 kgf-m, 68.7 lbf-ft)

5. No. 1 driven plate (5 – 7 pcs.)

12. Wave spring washer

: Apply engine oil.

6. No. 2 driven plate (1 pc.)

13. Clutch lifter driven cam

7. No. 2 drive plate (1 pc.)

14. Clutch lifter drive cam

5C-5 Clutch: 

Clutch Removal

B947H15306006

1) Drain engine oil. Refer to “Engine Oil and Filter 

Replacement” in Section 0B (Page 0B-10).

2) Lift and support the fuel tank with the prop stay. 

Refer to “Fuel Tank Removal and Installation” in 
Section 1G (Page 1G-9).

3) Disconnect the CKP sensor coupler (1).

4) Remove the clutch cover (2).

5) Remove the gasket (3) and dowel pins.

6) Remove the clutch springs and pressure plate (4).

NOTE

Loosen the clutch spring set bolts little by 
little and diagonally.

 

7) Remove the clutch drive plates (5) and driven plates 

(6).

8) Remove the spring washer (7) and its seat (8).

1

I947H1530042-02

2

I947H1530002-01

3

I947H1530003-01

4

I947H1530004-01

5

6

I947H1530005-01

7

8

I947H1530006-01

Clutch: 5C-6

9) Remove the thrust washer (9), bearing (10) and 

clutch push piece (11).

10) Remove the clutch push rod (12).

NOTE

If it is difficult to pull out the push rod (12), 
use a magnetic hand or wire.

 

11) Unlock the clutch sleeve hub nut.

12) Hold the clutch sleeve hub with the special tool.

Special tool

(A):  09920–53740 (Clutch sleeve hub 

holder)

13) Remove the clutch sleeve hub nut.

14) Remove the spring washer (13), washer (14) and 

clutch sleeve hub (15).

15) Remove the seat washer (16) from the clutch sleeve 

hub.

16) Remove the wave spring washers (17) and clutch 

lifter driven cam (18).

9

11

10

I947H1530007-01

12

I947H1530008-01

I947H1530009-01

(A)

I947H1530010-01

13

14

15

I947H1530011-01

16

I947H1530012-01

17

18

I947H1530013-01

5C-7 Clutch: 

17) Remove the clutch lifter drive cam (19) and thrust 

washer (20).

18) Remove the spacer (21) and bearing (22).

19) Remove the primary driven gear assembly (23).

NOTE

If it is difficult to remove the primary driven 
gear, rotate the crankshaft.

 

Clutch Installation

B947H15306007

1) Install the primary driven gear assembly (1).

CAUTION

!

 

• If it is difficult to install the primary driven 

gear, rotate the crankshaft.

• Be sure to engage the oil pump drive 

sprocket with the primary driven gear.

 

2) Install the spacer (2) and bearing (3), and apply 

engine oil to them.

3) Install the thrust washer (4).

4) Install the seat washer (5) to the clutch sleeve hub 

(6).

5) Install the wave spring washers (7) and clutch lifter 

driven cam (8).

6) Apply engine oil to the contacting surfaces of the 

clutch sleeve hub, clutch lifter drive cam and clutch 
lifter driven cam.

20

19

I947H1530014-01

21

22

23

I947H1530015-01

1

I947H1530016-01

2

3

I947H1530017-01

4

I947H1530018-01

5

6

I947H1530019-01

Clutch: 5C-8

7) Install the clutch lifter drive cam (9).

8) Install the clutch sleeve hub, washer (10) and spring 

washer (11).

NOTE

The conical curve side of spring washer (11) 
faces outside.

 

9) Hold the clutch sleeve hub with the special tool.

Special tool

(A):  09920–53740 (Clutch sleeve hub 

holder)

10) Tighten the clutch sleeve hub nut to the specified 

torque.

Tightening torque
Clutch sleeve hub nut (a):  95 N·m (9.5 kgf-m, 
68.7 lbf-ft)

11) Lock the clutch sleeve hub nut with a center punch.

12) Install the clutch push rod (12) into the countershaft.

13) Install the clutch push piece (13), bearing (14) and 

thrust washer (15) to the countershaft.

NOTE

Thrust washer (15) is located between the 
pressure plate and bearing (14).

 

8

7

9

I947H1530020-02

11

10

I947H1530021-01

11

10

I837H1530024-02

(A)

(a)

I947H1530022-01

I947H1530023-01

12

I947H1530024-01

13

14

15

I947H1530025-01

5C-9 Clutch: 

14) Install the spring washer seat (16) and spring washer 

(17) onto the clutch sleeve hub correctly.

15) Apply engine oil to the clutch drive plates.

16) Insert the clutch drive plates and driven plate one by 

one into the clutch sleeve hub in the prescribed 
order.

NOTE

Insert the outermost No. 1 drive plate claws 
“A” to the other slits “B” of clutch housing as 
shown in the figure.

 

NOTE

Two kinds of drive plate (No. 1 and No. 2) are 
equipped in the clutch system, they can be 
distinguished by inside diameter.

 

NOTE

Three kinds of the driven plate (No. 1, No. 2 
and No. 3) are equipped in the clutch system, 
they can be distinguished by color and 
thickness.
The No. 1, No. 2 and No. 3 driven plates are 8 
pcs. in total.
5 – 7 pcs. of No. 1 driven plates are used with 
1 pc. of No. 2 and 0 – 2 pc(-s). of No. 3 driven 
plate(-s) as a set. The No. 3 driven plate(-s) 
should be installed in pressure plate side.

 

17) Install the pressure plate (23).

NOTE

When install the pressure plate, fit the 
convex part “D” of the pressure plate onto 
the concave part “E” of the clutch sleeve 
hub.

 

18) Install the clutch springs and set bolts.

18. No. 2 drive plate (1 pc.)

19. No. 1 drive plate (8 pcs.)

20. No. 2 driven plate (1 pc.)

21. No. 1 driven plate (5 – 7 pcs.)

22. No. 3 driven plate (0 – 2 pcs.)

“C”: Direction of outside

16

17

I837H1530028-01

“A”

“B”

I947H1530026-02

18

21 22

21

/

“C”

19

20

I947H1530027-01

Drive plate

I.D.

No. 1

112 mm (4.41 in)

No. 2

122.5 mm (4.82 in)

Driven plate

Thickness

Color

No. 1

2.3 mm (0.09 in)

Silver

No. 2

2.3 mm (0.09 in)

Gray (Heat treated)

No. 3

2.6 mm (0.10 in)

Silver

“D”

“E”

23

I947H1530028-02

Clutch: 5C-10

19) Tighten the clutch spring set bolts to the specified 

torque.

Tightening torque
Clutch spring set bolt:  10 N·m (1.0 kgf-m, 7.0 lbf-
ft)

NOTE

Tighten the clutch spring set bolt little by 
little and diagonally.

 

20) Loosen the lock-nut (24) and turn in the clutch 

release adjusting screw (25) until resistance is felt.

21) From that position, turn out the clutch release 

adjusting screw (25) 1 turn and tighten the lock-nut 
(24) while holding the screw (25).

Tightening torque
Clutch release adjusting screw lock-nut:  6 N·m (
0.6 kgf-m, 4.5 lbf-ft)

22) Apply bond lightly to the mating surfaces at the 

parting line between the upper and lower crankcases 
as shown in the figure.

:  Sealant 99000–31140 (SUZUKI BOND 

No.1207B or equivalent)

23) Install the dowel pins and new gasket (26).

CAUTION

!

 

Use new gasket to prevent oil leakage.

 

24) Apply bond lightly to the CKP sensor grommet.

:  Sealant 99000–31140 (SUZUKI BOND 

No.1207B or equivalent)

25) Apply molybdenum oil solution to the starter torque 

limiter/idle gear No. 2 shaft holes.

M/O:  Molybdenum oil  (MOLYBDENUM OIL 
SOLUTION)

I947H1530029-01

25

24

I947H1530030-02

I947H1530031-01

26

I947H1530032-01

I947H1530033-02