Suzuki GSX-R 1000 Service Manual: Clutch parts inspection

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

Clutch drive and driven plate

Measure the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch drive plate thickness service limit (no. 1 And no. 2 Drive plates): 2.92 Mm (0.115 In)

Measure the claw width of drive plates with a vernier calipers. Replace the drive plates found to have worn down to the limit.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch drive plate claw width service limit (no. 1 And no. 2 Drive plates): 12.90 Mm (0.508 In)

Measure each driven plate for distortion with a thickness gauge and surface plate.

Replace driven plates which exceed the limit.

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

Clutch driven plate distortion service limit (no. 1, No. 2 And no.3 Driven plates): 0.10 Mm (0.004 In)

Clutch spring

Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.

Replace all the springs if any spring is not within the limit.

Special tool (a): 09900–20102 (vernier calipers
(200 mm))

Clutch spring free length service limit: 55.3 Mm (2.18 In)

Clutch release bearing

Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.

Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

Push rod (right)

Inspect the push rod for wear and damage.

If any defects are found, replace the push rod with a new one.

Clutch sleeve hub and primary driven gear assembly

Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.

Wave spring washer

Measure the free height “a” of each wave spring washer with a vernier calipers.

If each wave spring washer height “a” is not within the specified limit, replace it with a new one.

Special tool : 09900–20102 (vernier calipers (200
mm))

Wave spring washer height “a” service limit: 4.30 Mm (0.169 In)

Clutch lifter drive cam and clutch lifter driven cam

Inspect the clutch lifter drive cam and clutch lifter driven cam for wear and damage. If any defects are found, replace the clutch lifter drive cam or clutch lifter driven cam.