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:
Charging system symptom diagnosis
Condition
Possible cause
Correction / reference item
Generator does not
charge
Open- or short-circuited lead wires, or
loose lead connections.
Repair, replace or connect properly.
Short-circuited, grounded or open
generator coil.
Replace
...
Fuel mesh filter inspection and cleaning
Inspect the fuel mesh filter in the following procedures:
remove the fuel mesh filter. Refer to “fuel pump disassembly and
assembly” .
If the fuel mesh filter is clogged with foreign particles,
it hinders smooth gasoline flow resulting in loss of
engine power. Such a filter ...
Fuel tank cap
To open the fuel tank cap, insert
the ignition key into the lock and
turn it clockwise. With the key
inserted, lift up with the key and
open the fuel tank cap. To close
the fuel tank cap, push the cap
down firmly with the key in the cap
lock.
Fuel level
Fi ller neck
Wa ...