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

I've been meaning to post this for a while, that a few thousand kms after doing the mod, my clutch started grabbing again. After using Shell ultra oil previously, I've recently tried using Motul 300v, hoping it'd help, but my clutch still grabs. I guess if I replaced the spring washer again, it might fix it again.
Interestingly, the grabbing has never once been a problem after warming the bike up on the side stand, but it happens after I've been sitting at traffic lights, and it seems to be worse the longer I've been waiting there!

Problem solved. Perfect post

Well I just took it all apart drilled the holes (thank god for a drill press)

Updated washer and a new gasket and some +10% springs

First ride I would say it is a lot smoother when slipping the clutch out from 6K rpm and floats the front tire with no chatter. Still is a bit sticky but I think I just need to get some oil in the plates.

Many thanks to the OP for figuring this out and taking the time to document it all with pictures.

lordviper13 said:

I am in the process of doing this mod and just took the fiber out, I am wondering is the last fiber a different size, from the diagram it looks like they are all the same except the front one.

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Yep thats correct. The innermost plate has a larger inner diameter.

The outermost plate is different too. It should have black paint on the edge of one of the tabs

Looks like I get to look forward to doing this as well. Just picked up a K5 and it does the chatter/groaning thing when I need to get out of the hole quick. Probably order clutch kit too since it has 22300m on the clock.

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Fair play excellent write up. Going to do this to mine

Okay I read the entire thread and am about to give this a go. A few questions though.

Are the spring retainers absolutely necessary? If so were can I find these? Tillerpilot must not check in anymore.

Also those who opted for the spring only and no drilling. Is all still good?

Tezzmin said:

Are the spring retainers absolutely necessary? If so were can I find these? Tillerpilot must not check in anymore.

Also those who opted for the spring only and no drilling. Is all still good?

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It seems that the spring wave washer is the part that is most important. I drilled the holes, but it seems that when the washer gets older it gets softer, the heat from the engine and oil makes it softer when the bike is being ridden(the higher the engine temperature, the softer it gets), which means it flattens out too easily and doesn't do it's job. Also check the steel plate that the washer is in contact with for grooving(mine had quite a deep groove), which would make it worse. I'm about to replace the spring washer again, and will now just consider it a part that needs replacing regularly.

so would one say that the drilling of the extra holes has definitely made a difference or is it moreso the spring washer?

GIX750 said:

so would one say that the drilling of the extra holes has definitely made a difference or is it moreso the spring washer?

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Well, I'm about to replace the spring washer again because I'm experiencing the same sticky clutch again, even though I've drilled the three extra holes. So, I'd say it's the spring washer that is the main problem.

I am about to give this a try. Thanks to all for the info.

I'm about to do this mid this weekend. I ordered all the parts.a whilst popping into my local dealer and ordering the parts, the guy asked "Clutch Mod?" I was like "yeh, why?", he goes " well I recommend, or rather Suzuki on his sheet to remedy this problem recommends replacing the flat washer too!" This is part no. 13. Should I replace this? How many of you guys have?

Kosmickid99 said:

I'm about to do this mid this weekend. I ordered all the parts.a whilst popping into my local dealer and ordering the parts, the guy asked "Clutch Mod?" I was like "yeh, why?", he goes " well I recommend, or rather Suzuki on his sheet to remedy this problem recommends replacing the flat washer too!" This is part no. 13. Should I replace this? How many of you guys have?

Click to expand...

I just did this exactly like OP's instructions and so far it's great. If you already have the washer then replace it, but not needed.

HELP!!! Just done the mod albeit just the washer change. I followed the guide exactly with regards to orientation of the washer and plates.

As suggested previously, I put the bike on a stand and started in gear and let warm up. The clutch is making slight clattery sounds and when I try and pull the lever todisengage the clutch it won't disengage confirmed by when I press the rear brake the bike stalls. I'm worried about taking it for a ride like this in case it chucks me off. What could be the problem here guys?

All sorted now, clutch working perfectly. Thanks OP

i done this tonight, just replaced washer and it worked a treat, can finally do my GP take off from the lights again...

Thanks to all who contributed to this.

I carried out this mod last week, both drilling the holes and fitting the new washer, along with a brand new clutch pack as the bike has done 20k miles now.

I also fitted the spring retainers which I bought from Jim (tillerpilot) I must say, these are great bits of kit and highly recommended by me. Thanks a lot Jim!

I haven't ridden it out yet as it's winter, but I did start the bike and run it up to temperature, and disengage/engage the clutch and gears and all seems good.

I'll report back once I've ridden it out in the Spring, hopefully there will be a bag load of difference.

I did this mod today. Went smoothly enough by just following the instructions. I gave it 2 or 3 hard take offs and the juddering and screeching has stopped. It seems like this magic little fix has worked! Not sure for how long but so far so good! Thanks to the author and everyone else who contributed! :thumbup:burnout

Well, just to report.

Now I've had chance to get out and ride the bike, it feels much nicer so I'm very happy with that.

Thanks to everyone who contributed, a very good modification.


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