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Suzuki GSX-R 1000 Service Manual: Clutch lifter pin inspection and adjustment

Suzuki GSX-R 1000 Service Manual / Transmission / transaxle / Clutch / Repair instructions / Clutch lifter pin inspection and adjustment

Refer to clutch removal  and clutch installation .

Note

when inspection and adjusting the clutch lifter pin, it is not necessary to install the clutch onto the countershaft.

Inspect and adjust the clutch lifter pin in the following procedures:

  1.  assemble the following parts into the primary driven gear assembly.

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

Note

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

Suzuki GSX-R. Clutch lifter pin inspection and adjustment


  1. Remove the clutch assembly from the primary driven gear assembly.

Suzuki GSX-R. Clutch lifter pin inspection and adjustment


  1. Inspect the height a of clutch lifter pin at three positions using the thickness gauge. If the measurement is out of the specification, adjust the height a as shown in the figure.

Special tool : 0990020803 (thickness gauge)


Clutch lifter pin height a standard: 0.2 0.4 Mm (0.008 0.016 In)

Suzuki GSX-R. Clutch lifter pin inspection and adjustment


  1. Loosen the lock-nuts (1) and turn out the clutch lifter pin (2).
Note

each clutch lifter pin height should be as closely as possible.

Suzuki GSX-R. Clutch lifter pin inspection and adjustment


  1. Set the thickness gauge to 0.3 Mm (0.012 In).

Special tool (a): 0990020803 (thickness gauge)


  1. Place a proper flat plate on the thickness gauges and hold them by hand.
  2.  Slowly turn in the clutch lifter pin (2) until resistance is felt.
  3. Tighten the lock-nut (1).

Tightening torque clutch lifter pin lock-nut (b): 23 nm (2.3 Kgf-m, 16.5 Lbf-ft)

Suzuki GSX-R. Clutch lifter pin inspection and adjustment


Suzuki GSX-R. Clutch lifter pin inspection and adjustment


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Specifications
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Other materials:

Transmission components
2Nd drive gear 6Th drive gear 3Rd/4th drive gear 5Th drive gear Countershaft/1st drive gear Driveshaft 2Nd driven gear 6Th driven gear 3Rd driven gear 4Th driven gear 5Th driven gear 1St driven gear Gearshift cam stopper Gearshi ...

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Front wheel assembly construction
Brake disc bolt Brake caliper mounting bolt Front axle bolt Front axle pinch bolt Clearance 18 Nm (1.8 Kgf-m, 13.0 Lbf-ft) 39 Nm (3.9 Kgf-m, 28.0 Lbf-ft) 100 Nm (10 kgf-m, 72.5 Lbf-ft) 23 Nm (2.3 Kgf-m, 16.5 Lbf-ft) ...

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