Suzuki GSX-R 1000 Service Manual: 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 section 1g .
- Disconnect the ckp sensor coupler (1).
- Remove the clutch cover (2).
- Remove the gasket (3) and dowel pins.
- Remove the clutch springs and pressure plate (4).
| Note loosen the clutch spring set bolts little by little and diagonally. |
- Remove the clutch drive plates (5) and driven plates (6).
- Remove the spring washer (7) and its seat (8).
- Remove the thrust washer (9), bearing (10) and clutch push piece (11).
- Remove the clutch push rod (12).
| Note if it is difficult to pull out the push rod (12), use a magnetic hand or wire. |
- Unlock the clutch sleeve hub nut.
- Hold the clutch sleeve hub with the special tool.
Special tool
(a): 09920–53740 (clutch sleeve hub
holder)
- Remove the clutch sleeve hub nut.
- Remove the spring washer (13), washer (14) and clutch sleeve hub (15).
- Remove the seat washer (16) from the clutch sleeve hub.
- Remove the wave spring washers (17) and clutch lifter driven cam (18).
- Remove the clutch lifter drive cam (19) and thrust washer (20).
- Remove the spacer (21) and bearing (22).
- Remove the primary driven gear assembly (23).
| Note if it is difficult to remove the primary driven gear, rotate the crankshaft. |
Clutch components
Clutch pressure plate
Clutch push piece
No. 1 Drive plate (8 pcs.)
No. 3 Driven plate (0 – 2 pcs.)
No. 1 Driven plate (5 – 7 pcs.)
No. 2 Driven plate (1 pc.)
...
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 ...
Other materials:
Throttle cable play inspection and adjustment
Inspect throttle cable play
initially at 1 000 km (600 miles, 2 months) and every
6 000 km (4 000 miles, 12 months) thereafter
Inspect and adjust the throttle cable play “a” as follows:
Throttle cable play “a”
2.0 – 4.0 Mm (0.08 – 0.16 In)
Remove the boot (1).
Loosen the lock-nu ...
Rear shock absorber disposal
Refer to “rear shock absorber removal and installation” .
The rear shock absorber unit contains high-pressure
nitrogen gas.
Mishandling can cause explosion.
Keep away from fire and heat. High gas
pressure caused by heat can cause an
explosion.
Release gas ...
Front turn signal light removal and installation
Removal
Remove the screw.
Disconnect the front turn signal coupler (1).
Remove the turn signal light assembly (2).
Installation
Install the front turn signal light in the reverse order of
removal. ...