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Suzuki GSX-R 1000 Service Manual: Clutch installation

  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.

Suzuki GSX-R. Clutch installation


  1. Install the spacer (2) and bearing (3), and apply engine oil to them.

Suzuki GSX-R. Clutch installation


  1. Install the thrust washer (4).

Suzuki GSX-R. Clutch installation


  1. Install the seat washer (5) to the clutch sleeve hub (6).

Suzuki GSX-R. Clutch installation


  1. Install the wave spring washers (7) and clutch lifter driven cam (8).
  2.  Apply engine oil to the contacting surfaces of the clutch sleeve hub, clutch lifter drive cam and clutch lifter driven cam.
  3. Install the clutch lifter drive cam (9).

Suzuki GSX-R. Clutch installation


  1. Install the clutch sleeve hub, washer (10) and spring washer (11).
Note

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

Suzuki GSX-R. Clutch installation


Suzuki GSX-R. Clutch installation


  1. Hold the clutch sleeve hub with the special tool.

Special tool (a): 0992053740 (clutch sleeve hub
holder)

  1. Tighten the clutch sleeve hub nut to the specified torque.

Tightening torque clutch sleeve hub nut (a): 95 nm (9.5 Kgf-m, 68.7 Lbf-ft)

Suzuki GSX-R. Clutch installation


  1. Lock the clutch sleeve hub nut with a center punch.

Suzuki GSX-R. Clutch installation


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

Suzuki GSX-R. Clutch installation


  1. 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).

Suzuki GSX-R. Clutch installation


  1. Install the spring washer seat (16) and spring washer (17) onto the clutch sleeve hub correctly.

Suzuki GSX-R. Clutch installation


  1. Apply engine oil to the clutch drive plates.
  2.  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.

Suzuki GSX-R. Clutch installation


Suzuki GSX-R. Clutch installation


  1. No. 2 Drive plate (1 pc.)
  2. No. 1 Drive plate (8 pcs.)
  3. No. 2 Driven plate (1 pc.)
  4. No. 1 Driven plate (5 7 pcs.)
  5. No. 3 Driven plate (0 2 pcs.)
  6. Direction of outside

 

Note

two kinds of drive plate (no. 1 And no. 2) Are equipped in the clutch system, they can be distinguished by inside diameter.

Suzuki GSX-R. Clutch installation


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.

Suzuki GSX-R. Clutch installation


  1. 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.

Suzuki GSX-R. Clutch installation


  1. Install the clutch springs and set bolts.
  2. Tighten the clutch spring set bolts to the specified torque.

Tightening torque clutch spring set bolt: 10 nm (1.0 Kgf-m, 7.0 Lbfft)

Note

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

Suzuki GSX-R. Clutch installation


  1. Loosen the lock-nut (24) and turn in the clutch release adjusting screw (25) until resistance is felt.
  2.  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 nm ( 0.6 Kgf-m, 4.5 Lbf-ft)

Suzuki GSX-R. Clutch installation


  1. Apply bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown in the figure.

: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

Suzuki GSX-R. Clutch installation


  1. Install the dowel pins and new gasket (26).
Caution

use new gasket to prevent oil leakage.

Suzuki GSX-R. Clutch installation


  1. Apply bond lightly to the ckp sensor grommet.

: Sealant 9900031140 (suzuki
bond no.1207B or equivalent)

  1. Apply molybdenum oil solution to the starter torque limiter/idle gear no. 2 Shaft holes.

M/o: molybdenum oil (molybdenum oil solution)

Suzuki GSX-R. Clutch installation


  1. Install the clutch cover and tighten the clutch cover bolts.
Note

fit new gasket washer to the bolt f and clamp to the bolt g.

Suzuki GSX-R. Clutch installation


  1. Route the ckp sensor lead wire properly. Refer to wiring harness routing diagram in section 9a .
  2. ) Install the fuel tank. Refer to fuel tank removal and installation in section 1g .
  3.  Pour engine oil. Refer to engine oil and filter replacement in section 0b .
Clutch removal
Drain engine oil. Refer to engine oil and filter replacement in section 0b .  Lift and support the fuel tank with the prop stay. Refer to fuel tank removal and installation in secti ...

Clutch parts inspection
Refer to clutch removal  and clutch installation . Clutch drive and driven plate Note wipe off the engine oil from the drive and driven plates with a clean rag. Measure t ...

Other materials:

Ect sensor inspection
Refer to dtc c15 (p0115-h/l): ect sensor circuit malfunction in section 1a . Inspect the ect sensor in the following procedures:  remove the ect sensor. Refer to ect sensor removal and installation .  Connect the ect sensor (1) to the circuit tester and place it in the o ...

Exhaust control system description
The exhaust control system (excs) consists of the exhaust control valve (excv), exhaust control valve actuator (excva) and exhaust control valve cables (excv cables). Excv is installed in the exhaust pipe. Excva is mounted inside of the right frame. The excv is operated by the excva via the ...

Pair system hose routing diagram
Pair control solenoid valve Pair reed valve White marking (hidden side) Yellow marking Blue marking Red marking Face the clamp end to the top. Make sure the clamp is not contacted to the frame or air cleaner box. 90 45 15 ...

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