05/06 Gsxr 1000 Clutch Mod DIY w/ lots of Pics

284314 Views 478 Replies 186 Participants Last post by EddieRideFast, 3 mo ago

JetSpeedz

Discussion Starter · Apr 13, 2007 (Edited)

19

Here is my DIY contribution this great site. This is the clutch mod that has been discussed in the past. Thanks to Stocky for his contributions and others.

I have the PDF also for anyone interested to download here is the link Below. 56k users this is your best OPTION. Also if it expires pm me with your email and i will send it out.

http://www.savefile.com/files/636359

Enjoy!
-Ali-:cheers

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21 - 40 of 479 Posts

SPL170db

· #21 · Apr 16, 2007

Excellent write up Ali.

Thanks for taking the time.

duc995

· #22 · Apr 16, 2007

Great write up! I have an '06 and have never experienced a clutch problem so I am unsure what you are fixing...but you did a great job explaining it!!

jprochnow222

· #23 · Apr 17, 2007

I have a new 06 on the way and was going to do this mod right away but have decided to hold off for the time being and see if my clutch has the chatter as well. But good job with the how to and all the pics that are in it.

mpp12

· #24 · Apr 20, 2007

I did it, its almost free and I know that my cluch will last longer.

jprochnow222

· #25 · Apr 21, 2007

Did this mod and there is a big difference even on the 06. Very happy I did it but it took me 3 hours to do but well worth the time. Thanks for the write up.

JetSpeedz

Discussion Starter · #26 · Apr 21, 2007

no prob.. the hardest part is taking all the metal out other then that is cake

MannyMalice

· #27 · Apr 21, 2007

hey man nice job on the write up, but you could have stoped after you put the clutch washer in, that alone gets rid of the hard starts.

mikedownsouth

· #28 · Apr 21, 2007

Hey guys got a ? for ya. I had this mod done last week at my mechanic. I picked it up and test drove it done there street, not far. This is the only time I drove it so far. I've been really busy with work. Anyways first thing I noticed is putting it in first gear clunk and a lurch forward. Then trying to find neutral was a bitch. Will this smooth out after I get a chance to really ride it. Anyone have this problem at first. I know somebody mentioned already about the lurching forward and after a good ride it went away. Any thoughts would be great. thanx/////.

dflowers

· #29 · Apr 22, 2007

Many thanks to JetSpeedz and Stocky for discovering and/or doing a great write-up for this mod. I have never had serious clutch problems with my 06 but the last month or so the clutch was starting to whine every now and then-mostly from a cold start in first gear- and was starting to get just a little bit grabby sometimes. So I ordered the parts and printed out the great instructions and did the mod. It took me 2-3 hours and that was taking my time with no hurry. I had also installed this clutch lever:

http://stores.sportbiketrackgear.com/Detail.bok?no=196

Very pricey but I was after an easier clutch pull at the expense of a longer clutch engagement arc and this item is adjustble for that. The only downside besides the price was that the lever would not work with the clutch engine start switch-the little switch that forces you to pull in the clutch lever to start the bike. Not a big deal really.

The clutch mod went fine and I had no strange grabbiness or anything during my first ride after the mod. It worked great from the start. Now it works like a clutch is supposed to. Nice and predictable with no drama! The combination of the clutch mod and the new clutch lever has given me a much easier clutch pull and nice clutch function. Now it is on par with the hydraulic clutch on my RC51 in terms of ease of use.

Thanks again! I just printed out the procedure and went page by page and it was real clear and easy to follow. Great stuff!!!

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JetSpeedz

Discussion Starter · #30 · Apr 23, 2007

dflowers glad it worked out for you.. if you want an even softer pull you can always go with the hydraulic setup, i have the brembo 16x18 on mine and it works with one finger

Mike like others reported that is usually stops after the first ride.. I just hope the dealer when putting it back together made sure the oil pump gear was fully engaged if not then you could have a broken oil pump gear... so if the problem does not go away take it apart and check

cotton-power

· #31 · Apr 29, 2007

Did the clutch mod on my k6 thou, it coincided with installing a new set of drive and driven plates after cooking it, my only problem is this, the write up suggests the slipper clutch adjusting bolts should have 2 threads showing after 2 and 1/4 turns out, mine show 3 threads which basically measures as near as dam it to standard. The slipper action does not seem as good as it was before the mod, there is a slight rear wheel locking before slipping occurs. Is the 2 and 1/4 setting the optimum setting or can it be tweeked to give a different slipper action depending on rider preference?

SPL170db

· #32 · Apr 29, 2007

I did the mod this afternoon in between watching the races. In addition to drilling the oil holes and installing the 750 washer I also installed this spring locating collars that I picked up from Tillerpilot. Apparently from the looks of the pressure plate the springs can and do dig into the walls of the plate as they wander off center.

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JetSpeedz

Discussion Starter · #33 · Apr 29, 2007

cotton-power said:
Did the clutch mod on my k6 thou, it coincided with installing a new set of drive and driven plates after cooking it, my only problem is this, the write up suggests the slipper clutch adjusting bolts should have 2 threads showing after 2 and 1/4 turns out, mine show 3 threads which basically measures as near as dam it to standard. The slipper action does not seem as good as it was before the mod, there is a slight rear wheel locking before slipping occurs. Is the 2 and 1/4 setting the optimum setting or can it be tweeked to give a different slipper action depending on rider preference?

the more you screw in the lifter pins the more it will slip so you can adjust it till you feel its right for you.. in the DIY it states the same thing... :cheers

Kaz thanks for posting that.. i ordered a set from Jim just didnt get it in time... ill be putting them in next time i take it apart...

SPL170db

· #34 · Apr 29, 2007

JetSpeedz said:
Kaz thanks for posting that.. i ordered a set from Jim just didnt get it in time... ill be putting them in next time i take it apart...

WOTGixxer tried his hand at making them out of a lenthg of titanium bar stock that he found for sale on eBay. He made them to the specs that Stocky posted up (which I assume these are as well) only to find out that the Brock's springs that he was waiting to deliver actually have a smaller inner diameter than the stock springs, I guess to keep that from wandering out far enough to hit the sides.

grtfast

· #35 · Apr 30, 2007

does anyone know what exactly happens when the clutch is chattering and what it is that this mod does that fixes it? also, is the clutch "chatter" the grabby growling anomoly that I have experienced on hard launches?

JetSpeedz

Discussion Starter · #36 · Apr 30, 2007

sucks for WOTGixxer.. i personally like the stock spring feel and wouldnt really change it unless it was for drag purposes...

grtfast - if you experience any chatter this will fix it and its usually on launches so it may be the same thing your experiencing...

prodigy17

· #37 · Apr 30, 2007

I was hoping someone could help me out. I'm doing this clutch mod, but I see that a couple of you found or had made a special part to center the clutch springs on the bolts and keep them from being flung into the cover. I can't seem to find these anywhere. Can anyone help me out. Thanks

SPL170db

· #38 · Apr 30, 2007

prodigy17 said:
I was hoping someone could help me out. I'm doing this clutch mod, but I see that a couple of you found or had made a special part to center the clutch springs on the bolts and keep them from being flung into the cover. I can't seem to find these anywhere. Can anyone help me out. Thanks

PM "Tillerpilot", he's the one that made mine.

JetSpeedz

Discussion Starter · #39 · Apr 30, 2007

here is Jim's email and like Kaz said you can also reach him via PM [email protected]

SPL170db

· #40 · May 3, 2007

I just went for the first after doing all the modifications. Must say clutch feels MUCH smoother and more positive actuation. In addition, the 2 1/4 turns on the lifter pins seems to have created more slipper effect (less engine braking) than it was stock, which is cool with me. Coming down from hi-revs you get a small amount of engine braking, down low almost none.

Again, much thanks to Ali for consolidating all the info into one thread for everyone's reference.

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