Suzuki GSX-R 1000 Service Manual: 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)

1. Lift and support the fuel tank. Refer to “fuel tank removal and installation” in section 1g (page 1g- 9).
2.  Turn in the adjuster (1) all the way into the clutch lever assembly.

3. Loosen the lock-nut (2) and turn the clutch cable adjuster (3) to obtain proper cable play.

4. Remove the clutch release adjuster cap (4).
5.  Loosen the lock-nut (5) and turn out the clutch release adjusting screw (6) two or three rotations.
6.  From that position, slowly turn in the clutch release adjusting screw (6) until resistance is felt.
7. From this position, turn out the clutch release adjusting screw (6) 1 rotation, and tighten the locknut (5) while holding the screw (6).

Tightening torque clutch release adjusting screw lock-nut: 6 n·m ( 0.6 Kgf-m, 4.5 Lbf-ft)

8. Turn the cable adjuster (3) to obtain 10 – 15 mm (0.4 – 0.6 In) of free play “a” at the clutch lever end.
9.  Tighten the lock-nut (2).

10. Install the clutch release adjuster cap (4).

Tightening torque clutch release adjuster cap: 11 n·m (1.1 Kgf-m, 8.0 Lbf-ft)

11. Reinstall the fuel tank.