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:

Piston and piston ring inspection
Refer to piston ring removal and installation . Piston diameter Measure the piston diameter using the micrometer at 15 mm (0.6 In) a from the skirt end. If the piston diameter is less than the service limit, replace the piston. Special tool (a): 0990020203 (micrometer (50 75 mm)) Pis ...

Specifications
Service data Wattage unit: w Tightening torque specifications Reference: for the tightening torque of fastener not specified in this section, refer to tightening torque list in section 0c . ...

DTC c41 (p2505): ecm power input signal malfunction
Detected condition and possible cause Detected condition Possible cause C41/P2505 No voltage is applied to the ecm. Lead wire/coupler connection of ecm terminal to fuel fuse. Fuel fuse. Wiring diagram Troubleshooting C ...

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