Suzuki GSX-R1000. Service Manual

5C-11 Clutch:

26) 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”.

27) Route the CKP sensor lead wire properly. Refer to

“Wiring Harness Routing Diagram” in Section 9A
(Page 9A-7).

28) Install the fuel tank. Refer to “Fuel Tank Removal

and Installation” in Section 1G (Page 1G-9).

29) Pour engine oil. Refer to “Engine Oil and Filter

Replacement” in Section 0B (Page 0B-10).

Clutch Parts Inspection

B947H15306008

Refer to “Clutch Removal” (Page 5C-5) an d “Clutch
Installation” (Page 5C-7).

Clutch Drive and Driven Plate

NOTE

Wipe off the engine oil from the drive and
driven plates with a clean rag.

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)

“G”

“F”

I947H1530034-01

(A)

I649G1530056-03

(A)

I649G1530057-03

(B)

I649G1530058-03

(A)

I718H1530062-01

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Clutch: 5C-12

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.

I649G1530059-02

I947H1530035-01

I947H1530036-01

“A”

I837H1530043-01

I947H1530037-01

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5C-13 Clutch:

Clutch Lifter Pin Inspection and Adjustment

B947H15306009

Refer to “Clutch Removal” (Page 5C-5) an d “Clutch
Installation” (Page 5C-7).

NOTE

When inspection and adjusting the clutch
lifter pin, it is not necessary to install the
clutch onto the countershaft.

Inspect and adjust the clutch lifter pin in the following
procedures:

1) Assemble the following parts into the primary driven

gear assembly.

• Clutch sleeve hub

• Spring washer seat, spring washer

• Clutch drive plates, clutch driven plates

• Pressure plate

• Clutch springs, clutch springs set bolts

Tightening torque
Clutch spring set bolt (a): 10 N·m (1.0 kgf-m, 7.0
lbf-ft)

NOTE

Tighten the clutch spring set bolt little by
little and diagonally.

2) Remove the clutch assembly from the primary driven

gear assembly.

3) Inspect the height “A” of clutch lifter pin at three

positions using the thickness gauge. If the
measurement is out of the specification, adjust the
height “A” as shown in the figure.

Special tool

: 09900–20803 (Thickness gauge)

Clutch lifter pin height “A”
Standard: 0.2 – 0.4 mm (0.008 – 0.016 in)

4) Loosen the lock-nuts (1) and turn out the clutch lifter

pin (2).

NOTE

Each clutch lifter pin height should be as
closely as possible.

5) Set the thickness gauge to 0.3 mm (0.012 in).

Special tool

(A): 09900–20803 (Thickness gauge)

6) Place a proper flat plate on the thickness gauges

and hold them by hand.

7) Slowly turn in the clutch lifter pin (2) until resistance

is felt.

(a)

I947H1530038-01

I947H1530039-01

“A”

I837H1530044-01

I947H1530040-01

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Clutch: 5C-14

8) Tighten the lock-nut (1).

Tightening torque
Clutch lifter pin lock-nut (b): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)

Specifications

Service Data

B947H15307001

Clutch

Unit: mm (in)

Tightening Torque Specifications

B947H15307002

NOTE

The specified tightening torque is described in the following.
“Clutch Control System Components” (Page 5C-3)
“Clutch Components” (Page 5C-4)

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C
(Page 0C-9).

(A)

I837H1530046-02

(b)

I947H1530041-02

Item

Standard

Limit

Clutch drive plate thickness

No. 1 and 2

3.22 – 3.38 (0.127 – 0.133)

2.92 (0.115)

Clutch drive plate claw width

No. 1 and 2

13.7 – 13.8 (0.539 – 0.543)

12.9 (0.508)

Clutch driven plate distortion

—

0.10 (0.004)

Clutch spring free length

58.18 (2.29)

55.3 (2.18)

Clutch lifter pin height

0.2 – 0.4 (0.008 – 0.016)

—

Wave spring washer height

—

4.30 (0.169)

Clutch lever play

10 – 15 (0.4 – 0.6)

—

Clutch release screw

1 turn back

—

Fastening part

Tightening torque

Note

⋅

kgf-m

lbf-ft

Clutch sleeve hub nut

9.5

68.7

)

(Page 5C-8)

Clutch spring set bolt

1.0 7.0

Clutch release adjusting screw lock-nut

0.6

4.5

)

(Page 5C-10)

Clutch lifter pin lock-nut

2.3

16.5

)

(Page 5C-14)

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5C-15 Clutch:

Special Tools and Equipment

Recommended Service Material

B947H15308001

NOTE

Required service material is also described in the following.
“Clutch Control System Components” (Page 5C-3)
“Clutch Components” (Page 5C-4)

Special Tool

B947H15308002

Material

SUZUKI recommended product or Specification

Note

Molybdenum oil

MOLYBDENUM OIL SOLUTION

—

)

(Page 5C-10)

Sealant

SUZUKI BOND No.1207B or
equivalent

P/No.: 99000–31140

09900–20102

09900–20803

Vernier calipers (200 mm)

Thickness gauge

09900–25008

09920–53740

Multi circuit tester set

Clutch sleeve hub holder

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Steering General Diagnosis: 6A-1

Steering

Steering General Diagnosis

Diagnostic Information and Procedures

Steering Symptom Diagnosis

B947H16104001

Condition

Possible cause

Correction / Reference Item

Heavy steering

Over tightened steering stem nut.

Adjust.

Broken bearing in steering stem.

Replace.

Distorted steering stem.

Replace.

Not enough pressure in tires.

Adjust.

Defective steering damper unit.

Replace.

Wobbly handlebars

Loss of balance between right and left
front forks.

Replace fork, adjust fork oil level or replace
spring.

Distorted front fork.

Repair or replace.

Distorted front axle or crooked tire.

Replace.

Loose steering stem nut.

Adjust.

Worn or incorrect tire or wrong tire
pressure.

Adjust or replace.

Worn bearing/race in steering stem.

Replace.

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6B-1 Steering / Handlebar:

Steering

Steering / Handlebar

Repair Instructions

Handlebar Components

B947H16206001

“A”

(b)

(a)

FWD

I947H1620001-05

1. Throttle grip

5. Right handlebar

“A”: Apply handle grip bond.

2. Grip rubber

6. Left handlebar

: 23 N

⋅

m (2.3 kgf-m, 16.5 lbf-ft)

3. Right handlebar switch box

7. Handlebar expander

: 5.5 N

⋅

m (0.55 kgf-m, 4.0 lbf-ft)

4. Left handlebar switch box

8. Handlebar balancer

: Apply grease.

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Steering / Handlebar: 6B-2

Handlebar Removal and Installation

B947H16206002

Removal

1) Remove the following parts from the left handlebar.

a) Left handlebar switch box (1)

b) Handlebar balancer (2)

c) Grip rubber (3)

d) Clutch cable (4)

2) Remove the following parts from the right handlebar.

a) Right handlebar switch box (5)

b) Handlebar balancer (6)

c) Throttle grip (7)

d) Front brake master cylinder (8)

CAUTION

Do not turn the front brake master cylinder
upside down.

3) Loosen the handlebar clamp bolts (9) and front fork

upper clamp bolts (10).

4) Remove the steering stem head nut (11) and washer

(12).

5) Remove the steering stem upper bracket assembly

(13).

NOTE

Place a rag under the steering stem upper
bracket to prevent scratching the body
cowling and the combination meter.

6) Remove the handlebars (14) upward.

I947H1620002-01

I947H1620003-01

I947H1620004-01

I947H1620005-01

I947H1620006-01

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6B-3 Steering / Handlebar:

7) Remove the clutch lever assembly (15) from the left

handlebar.

Installation

Install the handlebars in the reverse order of removal.
Pay attention to the following points:

• When installing the clutch lever assembly to the left

handlebar, align the slit of lever holder with the punch
mark “A”.

• Install the handlebars temporarily to the front forks.

• Install the upper bracket (1), washer (2) and steering

stem head nut (3) temporarily.

NOTE

Face the chamfer side of the washer
downward.

• Insert the protrusion “B” of the handlebar into the hole

“C” of the steering stem upper bracket.

• Tighten the front fork upper clamp bolts (4) and

handlebar clamp bolts (5) to the specified torque.

Tightening torque
Front fork upper clamp bolt (a): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)
Handlebar clamp bolt (b): 23 N·m (2.3 kgf-m, 16.5
lbf-ft)

• Tighten the steering stem head nut (6) to the specified

torque.

Tightening torque
Steering stem head nut (c): 90 N·m (9.0 kgf-m,
65.0 lbf-ft)

I947H1620007-01

“A”

I947H1620009-01

I947H1620008-01

“C”

“B”

I947H1620010-01

(a)

(b)

(a)

I947H1620011-01

(c)

I947H1620012-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Steering / Handlebar: 6B-4

• Install the front brake master cylinder. Refer to “Front

Brake Master Cylinder Assembly Removal and
Installation” in Section 4A (Page 4A-10).

• Apply grease to the end of the throttle cables and

cable pulley.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

• Insert the projection “D” of the right handlebar switch

box into the hole of the right handlebar.

• Apply a handle grip bond “E” onto the left handlebar

before installing the handlebar grip.

: Handle grip bond (Handle Grip Bond

(commercially available))

• Insert the projection “F” of the left handlebar switch

box into the hole of the left handlebar.

• After installing the steering, the following adjustments

are required before driving.

– Throttle cable routing (Refer to “Throttle Cable

Routing Diagram” in Section 1D (Page 1D-2))

– Clutch cable routing (Refer to “Throttle Cable

Routing Diagram” in Section 1D (Page 1D-2))

– Throttle cable play (Refer to “Throttle Cable Play

Inspection and Adjustment” in Section 1D
(Page 1D-7))

– Clutch cable play (Refer to “Clutch Cable Play

Inspection and Adjustment” in Section 0B
(Page 0B-14))

Handlebars Inspection

B947H16206003

Refer to “Handlebar Removal and Installation” (Page 6B-
2).
Inspect the handlebars for distortion and damage.
If any defect is found, replace the handlebar with a new
one.

“D”

I947H1620013-01

“E”

I947H1620014-01

“F”

I947H1620015-01

I947H1620016-01

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6B-5 Steering / Handlebar:

Steering Components

B947H16206004

(a)

(d)

(b)

FWD

(c)

I947H1620017-04

1. Steering stem head nut

7. Dust seal

: 90 N

⋅

m (9.0 kgf-m, 65.0 lbf-ft)

2. Steering stem upper bracket

8. Steering stem upper bearing

: 80 N

⋅

m (8.0 kgf-m, 58.0 lbf-ft)

3. Steering stem lock-nut

9. Steering stem lower bearing

: 45 N

⋅

m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/2 – 1/4

4. Washer

10. Lower seal

: 23 N

⋅

m (2.3 kgf-m, 16.5 lbf-ft)

5. Steering stem nut

11. Steering stem lower bracket

: Apply grease.

6. Dust seal cover

12. Steering stem lower bearing inner race

: Do not reuse.

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Steering / Handlebar: 6B-6

Steering Damper Construction

B947H16206005

Steering / Steering Damper Removal and
Installation

B947H16206006

Removal
Steering damper

1) Turn the ignition switch OFF.

2) Disconnect the steering damper solenoid coupler

(1).

3) Remove the lower bracket cover (2).

4) Remove the steering damper mounting nut (3) while

holding the lock-nut (4).

5) Remove the steering damper mounting bolt (5).

6) Remove the steering damper (6).

Steering

1) Support the motorcycle with a jack or wooden block.

CAUTION

Do not work by using side stand. Do not
support the motorcycle with exhaust pipe.
Make sure that the motorcycle is supported
securely.

2) Remove the front wheel assembly. Refer to “Front

Wheel Assembly Removal and Installation” in
Section 2D (Page 2D-4).

3) Remove the front forks. Refer to “Front Fork

Removal and Installation” in Section 2B (Page 2B-2).

4) Remove the steering damper. Refer to “Steering /

Steering Damper Removal and Installation”
(Page 6B-6).

5) Lift and support the fuel tank. Refer to “Fuel Tank

Removal and Installation” in Section 1G (Page 1G-
9).

1. Steering damper

2. Dust seal

3. Bearing

: 23 N

⋅

m (2.3 kgf-m, 16.5 lbf-ft)

: Apply grease.

(a)

FWD

I837H1620040-01

I947H1620018-01

I947H1620019-01

I947H1620020-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

6B-7 Steering / Handlebar:

6) Remove the air cleaner box. Refer to “Air Cleaner

Box Removal and Installation” in Section 1D
(Page 1D-7).

7) Disconnect the ignition switch lead wire coupler (1)

and immobilizer antenna lead wire coupler (For E-
02, 19, 24, 51) (2).

8) Remove the brake hose clamp bolt (3).

9) Remove the steering stem head nut (4) and washer

(5).

10) Remove the steering stem upper bracket assembly

(6).

NOTE

It is not necessary to remove the ignition
switch from the upper bracket when
servicing the steering system.

11) Remove the steering stem lock-nut (7), washer and

steering stem nut (8) with the special tools.

NOTE

When loosening the stem nuts, hold the
steering stem lower bracket to prevent it from
falling.

Special tool

(A): 09940–14911 (Steering stem nut socket

wrench)

(B): 09940–14960 (Steering stem nut socket

wrench)

12) Remove the steering stem lower bracket.

13) Remove the dust seal cover (9), dust seal (10),

upper bearing inner race (11) and upper bearing
(12).

I947H1620021-01

I947H1620041-01

I947H1620022-01

(A)

(B)

I947H1620023-01

I947H1620024-01

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Steering / Handlebar: 6B-8

Installation

Install the steering in the reverse order of removal.
Pay attention to the following points:

Bearing

• Apply grease to the bearings, bearing races and dust

seals before remounting the steering stem.

: Grease 99000–25010 (SUZUKI SUPER

GREASE “A” or equivalent)

Steering stem nut

• Tighten the steering stem nut (1) to the specified

torque with the special tools.

Special tool

(A): 09940–14911 (Steering stem nut socket

wrench)

(B): 09940–14960 (Steering stem nut socket

wrench)

Tightening torque
Steering stem nut (a): 45 N

⋅

m (4.5 kgf-m, 32.5 lbf-

ft) then turn back 1/4 – 1/2

• Turn the steering stem lower bracket about five or six

times to the left and right so that the angular ball
bearings seat properly.

• Loosen the steering stem nut 1/4 – 1/2 turn “a”.

NOTE

This adjustment will vary from motorcycle to
motorcycle.

• When installing the washer (2), align the lug of the

washer to the groove of the steering stem.

• Tighten the steering stem lock-nut (3) to the specified

torque with the special tools.

Special tool

(A): 09940–14911 (Steering stem nut socket

wrench)

(B): 09940–14960 (Steering stem nut socket

wrench)

Tightening torque
Steering stem lock-nut (b): 80 N·m (8.0 kgf-m,
58.0 lbf-ft)

I947H1620025-01

I947H1620026-01

(A)

(B)

(a)

I947H1620027-01

“ a ”

I947H1620028-01

I947H1620029-01

(A)

(B)

(b)

I947H1620030-01

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Suzuki GSX-R1000. Service Manual - part 36