Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: 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 the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch drive plate thickness service limit (no. 1 And no. 2 Drive plates): 2.92 Mm (0.115 In)

Suzuki GSX-R. Clutch drive and driven plate


Measure the claw width of drive plates with a vernier calipers. Replace the drive plates found to have worn down to the limit.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch drive plate claw width service limit (no. 1 And no. 2 Drive plates): 12.90 Mm (0.508 In)

Suzuki GSX-R. Clutch drive and driven plate


Measure each driven plate for distortion with a thickness gauge and surface plate.

Replace driven plates which exceed the limit.

Special tool (b): 09900–20803 (thickness gauge)


Clutch driven plate distortion service limit (no. 1, No. 2 And no.3 Driven plates): 0.10 Mm (0.004 In)

Suzuki GSX-R. Clutch drive and driven plate


Clutch spring

Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.

Replace all the springs if any spring is not within the limit.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch spring free length service limit: 55.3 Mm (2.18 In)

Suzuki GSX-R. Clutch spring


Clutch release bearing

Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.

Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

Suzuki GSX-R. Clutch release bearing


Push rod (right)

Inspect the push rod for wear and damage.

If any defects are found, replace the push rod with a new one.

Suzuki GSX-R. Push rod


Clutch sleeve hub and primary driven gear assembly

Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.

Suzuki GSX-R. Clutch sleeve hub and primary driven gear assembly


Wave spring washer

Measure the free height “a” of each wave spring washer with a vernier calipers.

If each wave spring washer height “a” is not within the specified limit, replace it with a new one.

Special tool : 09900–20102 (vernier calipers (200
mm))

Wave spring washer height “a” service limit: 4.30 Mm (0.169 In)

Suzuki GSX-R. Wave spring washer


Clutch lifter drive cam and clutch lifter driven cam

Inspect the clutch lifter drive cam and clutch lifter driven cam for wear and damage. If any defects are found, replace the clutch lifter drive cam or clutch lifter driven cam.

Suzuki GSX-R. Clutch lifter drive cam and clutch lifter driven cam


Clutch installation
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 ...

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. ...

Other materials:

Conrod crank pin bearing removal and installation
Refer to “engine bottom side disassembly” (page 1d- 49). Refer to “engine bottom side assembly” . Removal Remove the conrod crank pin bearings (1). Note  do not remove the bearings (1) unless absolutely necessary.  Make a note of where the bearings are removed ...

Gearshift shaft / gearshift cam plate removal and installation
Removal Remove the engine sprocket cover. Refer to “engine sprocket removal and installation” in section 3a .  Remove the clutch components. Refer to “clutch removal” in section 5c .  Remove the snap ring (1) and washer (2) from the gearshift shaft. Special tool : 09900–06 ...

Swingarm removal and installation
Removal Cut the drive chain. Refer to “drive chain replacement” in section 3a .  Remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation” in section 2d .  Disconnect the rear brake hose from the brake hose clamp (1). Remove the brake ho ...

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