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:
Steering / steering damper removal and
installation
Removal
steering damper
Turn the ignition switch off.
Disconnect the steering damper solenoid coupler
(1).
Remove the lower bracket cover (2).
Remove the steering damper mounting nut (3) while
holding the lock-nut (4).
Remove the steering damper mounting bolt ( ...
Starting the engine
Before attempting to start the
engine, make sure:
The transmission is in neutral.
The engine stop switch is in
the "" position.
Note: this motorcycle has a
starter interlock system for the
ignition and starter circuit. The
engine can only be started if:
...
Steering damper maintenance
Keep the steering damper
shaft 1 clean at all times.
Wipe off any oil residue with a
cloth.
Do not confuse the grease-like
residue on the steering damper's
shaft with an oil leak. Collection of
this residue is normal and is from
oil seal lubricant used in the
damper.
Yo ...