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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


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 ...

Specifications
Service data Clutch unit: mm (in) Tightening torque specifications Note the specified tightening torque is described in the following. Clutch control system components&nbs ...

Other materials:

Rear brake disc inspection
Brake disc thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (a): 0990020205 (micrometer (0 25 mm)) Brake disc thickness service ...

Pair control solenoid valve removal and installation
Removal Lift and support the fuel tank with the prop stay. Refer to fuel tank removal and installation in section 1g .  Remove the air cleaner box. Refer to air cleaner box removal and installation in section 1d . Remove the pair control solenoid valve (1) along with the pair ...

Left handlebar
Clutch lever 1 The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting the transmission gear. Squeezing the lever disengages the clutch. Headlight flasher switch 2 Press the switch to light the headlight. Dimmer switch 3 " " ...

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