Suzuki GSX-R 1000 Service Manual: 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 drive
sprocket with the primary driven gear.
|
- Install the spacer (2) and bearing (3), and apply
engine oil to them.
- Install the thrust washer (4).
- Install the seat washer (5) to the clutch sleeve hub
(6).
- Install the wave spring washers (7) and clutch lifter
driven cam (8).
- Apply engine oil to the contacting surfaces of the
clutch sleeve hub, clutch lifter drive cam and clutch
lifter driven cam.
- Install the clutch lifter drive cam (9).
- Install the clutch sleeve hub, washer (10) and spring
washer (11).
Note
the conical curve side of spring washer (11)
faces outside. |
- Hold the clutch sleeve hub with the special tool.
Special tool
(a): 09920–53740 (clutch sleeve hub
holder)
- Tighten the clutch sleeve hub nut to the specified
torque.
Tightening torque
clutch sleeve hub nut (a): 95 n·m (9.5 Kgf-m,
68.7 Lbf-ft)
- Lock the clutch sleeve hub nut with a center punch.
- Install the clutch push rod (12) into the countershaft.
- Install the clutch push piece (13), bearing (14) and
thrust washer (15) to the countershaft.
Note
thrust washer (15) is located between the
pressure plate and bearing (14). |
- Install the spring washer seat (16) and spring washer
(17) onto the clutch sleeve hub correctly.
- Apply engine oil to the clutch drive plates.
- Insert the clutch drive plates and driven plate one by
one into the clutch sleeve hub in the prescribed
order.
Note
insert the outermost no. 1 Drive plate claws
“a” to the other slits “b” of clutch housing as
shown in the figure. |
- No. 2 Drive plate (1 pc.)
- No. 1 Drive plate (8 pcs.)
- No. 2 Driven plate (1 pc.)
- No. 1 Driven plate (5 – 7 pcs.)
- No. 3 Driven plate (0 – 2 pcs.)
- Direction of outside
|
Note
two kinds of drive plate (no. 1 And no. 2) Are
equipped in the clutch system, they can be
distinguished by inside diameter. |
Note
three kinds of the driven plate (no. 1, No. 2
And no. 3) Are equipped in the clutch system,
they can be distinguished by color and
thickness.
The no. 1, No. 2 And no. 3 Driven plates are 8
pcs. In total.
5 – 7 Pcs. Of no. 1 Driven plates are used with
1 pc. Of no. 2 And 0 – 2 pc(-s). Of no. 3 Driven
plate(-s) as a set. The no. 3 Driven plate(-s)
should be installed in pressure plate side. |
- Install the pressure plate (23).
Note
when install the pressure plate, fit the
convex part “d” of the pressure plate onto
the concave part “e” of the clutch sleeve
hub. |
- Install the clutch springs and set bolts.
- Tighten the clutch spring set bolts to the specified
torque.
Tightening torque
clutch spring set bolt: 10 n·m (1.0 Kgf-m, 7.0 Lbfft)
Note
tighten the clutch spring set bolt little by
little and diagonally. |
- Loosen the lock-nut (24) and turn in the clutch
release adjusting screw (25) until resistance is felt.
- From that position, turn out the clutch release
adjusting screw (25) 1 turn and tighten the lock-nut
(24) while holding the screw (25).
Tightening torque
clutch release adjusting screw lock-nut: 6 n·m (
0.6 Kgf-m, 4.5 Lbf-ft)
- Apply bond lightly to the mating surfaces at the
parting line between the upper and lower crankcases
as shown in the figure.
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
- Install the dowel pins and new gasket (26).
Caution
use new gasket to prevent oil leakage. |
- Apply bond lightly to the ckp sensor grommet.
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
- Apply molybdenum oil solution to the starter torque
limiter/idle gear no. 2 Shaft holes.
M/o: molybdenum oil (molybdenum oil
solution)
- Install the clutch cover and tighten the clutch cover
bolts.
Note
fit new gasket washer to the bolt “f” and
clamp to the bolt “g”. |
- Route the ckp sensor lead wire properly. Refer to “wiring harness
routing diagram” in section 9a .
- ) Install the fuel tank. Refer to “fuel tank removal and installation”
in section 1g .
- Pour engine oil. Refer to “engine oil and filter replacement” in
section 0b .
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 secti ...
Refer to “clutch removal” and “clutch installation” .
Clutch drive and driven plate
Note
wipe off the engine oil from the drive and
driven plates with a clean rag.
Measure t ...
Other materials:
Steering damper maintenance
Keep the steering damper
shaft 1 clean at all times.
Wipe off any oil residue with a
cloth.
Do not confuse the grease-like
residue on the steering damper's
shaft with an oil leak. Collection of
this residue is normal and is from
oil seal lubricant used in the
damper.
Yo ...
Schematic and routing diagram
Engine lubrication system chart diagram
Engine lubrication circuit diagram
...
Pillion footrest construction
Pillion footrest
Spring
Ball
E-ring
Washer
O-ring
Footrest pin
Apply grease.
Do not reuse.
...