Suzuki GSX-R 1000 Service Manual: Clutch lifter pin inspection and adjustment

Refer to “clutch removal”  and “clutch installation” .

Inspect and adjust the clutch lifter pin in the following procedures:

1.  assemble the following parts into the primary driven gear assembly.

•  Clutch sleeve hub
•  spring washer seat, spring washer
•  clutch drive plates, clutch driven plates
•  pressure plate
•  clutch springs, clutch springs set bolts

Tightening torque clutch spring set bolt (a): 10 n·m (1.0 Kgf-m, 7.0 Lbf-ft)

2. Remove the clutch assembly from the primary driven gear assembly.

3. Inspect the height “a” of clutch lifter pin at three positions using the thickness gauge. If the measurement is out of the specification, adjust the height “a” as shown in the figure.

Special tool : 09900–20803 (thickness gauge)

Clutch lifter pin height “a” standard: 0.2 – 0.4 Mm (0.008 – 0.016 In)

4. Loosen the lock-nuts (1) and turn out the clutch lifter pin (2).

5. Set the thickness gauge to 0.3 Mm (0.012 In).

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

6. Place a proper flat plate on the thickness gauges and hold them by hand.
7.  Slowly turn in the clutch lifter pin (2) until resistance is felt.
8. Tighten the lock-nut (1).

Tightening torque clutch lifter pin lock-nut (b): 23 n·m (2.3 Kgf-m, 16.5 Lbf-ft)