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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:

Engine bottom side assembly
Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: Note apply engine oil to each running and sliding part before reassembling. Breather oil return plate When installing the breather oil return plate (1), apply thread loc ...

Clutch adjustment
Clutch cable play should be 1 0 - 15 mm (0.4 - 0.6 In) measured at the clutch lever end. Adjust clutch cable play according to the following procedure: Minor adjustment Turn the clutch cable adjuster 1 to provide the specified play. Major adjustment Turn in the adjuster 1 all the ...

Pillion footrest construction
Pillion footrest Spring Ball E-ring Washer O-ring Footrest pin Apply grease. Do not reuse. ...

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