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:
Specifications
Service data
Brake
unit: mm (in)
Tightening torque specifications
Note
the specified tightening torque is described in the following.
“Front brake hose routing diagram” “rear brake hose routing
diagram” “front brake master cylinder components” “rear
...
Horn inspection
Note
if the horn sound condition is normal, it is not
necessary to inspect the horn button
continuity.
Horn button inspection
Remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the left handlebar switch lead ...
Starter motor will not run
Note
make sure the fuses are not blown and the battery is fully-charged
before diagnosing.
Troubleshooting
Step
Action
Yes
No
1
Shift the transmission into neutral.
Grasp the clutch lever, turn on the ignition switch ...