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): 09920–53740 (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:

Front brake master cylinder parts inspection
Refer to “front brake master cylinder / brake lever disassembly and assembly” . Master cylinder Inspect the master cylinder bore for any scratches or other damage Piston / rubber parts Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup ...

Precautions
Precautions for wheel and tire Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control.  Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear. ...

Excva pulley inspection
Inspect the excva pulley in the following procedures:  remove the excva pulley. Refer to “excv cable removal and installation” .  Visually inspect the excva pulley for wear and damage. If there is anything unusual, replace the pulley with a new one. Install the pulle ...

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