Toyota RAV4 manuals

Suzuki GSX-R 1000 Service Manual: Clutch removal

  1. Drain engine oil. Refer to engine oil and filter replacement in section 0b .
  2.  Lift and support the fuel tank with the prop stay.

    Refer to fuel tank removal and installation in section 1g .

  3.  Disconnect the ckp sensor coupler (1).

Suzuki GSX-R. Clutch removal


  1. Remove the clutch cover (2).

Suzuki GSX-R. Clutch removal


  1. Remove the gasket (3) and dowel pins.

Suzuki GSX-R. Clutch removal


  1. Remove the clutch springs and pressure plate (4).
Note

loosen the clutch spring set bolts little by little and diagonally.

Suzuki GSX-R. Clutch removal


  1. Remove the clutch drive plates (5) and driven plates (6).

Suzuki GSX-R. Clutch removal


  1. Remove the spring washer (7) and its seat (8).

Suzuki GSX-R. Clutch removal


  1. Remove the thrust washer (9), bearing (10) and clutch push piece (11).

Suzuki GSX-R. Clutch removal


  1. Remove the clutch push rod (12).
Note

if it is difficult to pull out the push rod (12), use a magnetic hand or wire.

Suzuki GSX-R. Clutch removal


  1. Unlock the clutch sleeve hub nut.

Suzuki GSX-R. Clutch removal


  1. Hold the clutch sleeve hub with the special tool.

Special tool (a): 0992053740 (clutch sleeve hub
holder)

  1. Remove the clutch sleeve hub nut.

Suzuki GSX-R. Clutch removal


  1. Remove the spring washer (13), washer (14) and clutch sleeve hub (15).

Suzuki GSX-R. Clutch removal


  1. Remove the seat washer (16) from the clutch sleeve hub.

Suzuki GSX-R. Clutch removal


  1. Remove the wave spring washers (17) and clutch lifter driven cam (18).

Suzuki GSX-R. Clutch removal


  1. Remove the clutch lifter drive cam (19) and thrust washer (20).

Suzuki GSX-R. Clutch removal


  1. Remove the spacer (21) and bearing (22).
  2.  Remove the primary driven gear assembly (23).
Note

if it is difficult to remove the primary driven gear, rotate the crankshaft.

Suzuki GSX-R. Clutch removal


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:

Gearshift lever construction
Gearshift lever bracket Gearshift lever shaft Washer Snap ring Gearshift lever Footrest top surface 65 75 Mm (2.6 3.0 In) 28 Nm (2.8 Kgf-m, 20.0 Lbf-ft) 40 Nm (4.0 Kgf-m, 29.0 Lbf-ft) Apply grease. Grease. ...

Clutch cable play inspection and adjustment
Inspect clutch cable play every 6 000 km (4 000 miles, 12 months) Inspect and adjust the clutch cable play a as follows. Clutch cable play a 10 15 mm (0.4 0.6 In) Lift and support the fuel tank. Refer to fuel tank removal and installation in section 1g (page 1g- 9).   ...

Exterior parts construction
Upper cowling bracket : set the punch mark to the front and upper side. Rear view mirror cushion : set the dent side to inside. To frame To headlight assembly To sprocket cove To side-stand bracket ...

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