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

judder spring only fixed road bike, didnt with race back, looks like im gonna have to drill basket

StuartV said:

I'm looking at the fiche for clutch parts on MRCycles.com. They list 3 different options for one of the metal clutch plates. How do I know which one I need?

Or is it that I need 9 of one of the 3 types list and none of the other 2?

It kind of looks like maybe 10 and 11 are just later revisions of the original. So I should just order 9 x of #11?

9
PLATE, CLUTCH DRIVEN (T:2.3)
21451-41G00
$10.64

10
PLATE, CLUTCH DRIVEN (T:2.0)
21451-41G10
$10.64

11
PLATE, CLUTCH DRIVEN (T:2.6)
21451-41G20

Click to expand...

The one you need is 21472-41G10

Thanks. I was on MRCycles about to order all the individual plates and springs. It was going to be a serious chunk of change! Fortunately, I happened to notice they sell a complete kit from Suzuki that has all the plates, springs, and a gasket for $130. I looked around some more and got it from Oneida Suzuki for $105!

It doesn't say which part number it comes with for the plates, but I assume whatever it comes with will be fine.

BTW, any clue what those other plates are that I listed? I would have thought the 41G20 might be an updated/newer version of the 41G10.

StuartV said:

Thanks. I was on MRCycles about to order all the individual plates and springs. It was going to be a serious chunk of change! Fortunately, I happened to notice they sell a complete kit from Suzuki that has all the plates, springs, and a gasket for $130. I looked around some more and got it from Oneida Suzuki for $105!

It doesn't say which part number it comes with for the plates, but I assume whatever it comes with will be fine.

BTW, any clue what those other plates are that I listed? I would have thought the 41G20 might be an updated/newer version of the 41G10.

Click to expand...

$105 is pretty good... I think you'll be fine with the kit but I think you'll need to make sure it comes with the new version of the wave washer which I'm sure it does

With regard to the different driven plate thickness, you'll see the same thing on page 3-96 of the service manual. Except there it's the outermost plate vs. next to the outermost in the fiche. I have two guesses regarding what it's about and both relate to pack thickness. One is that there's a target thickness when new and the varying thickness allows you to better reach it. The other is that it allows you to compensate for wear on the drive plates. It's been in the service manual from the beginning so it's not a part update.

P.S. Please measure the plates in the kit when you get it and report back here. It's my impression that the kit includes the springs, drive plates, driven plates, and the cover gasket.

No worries on that. I ordered the correct wave washer separately. :-} I'm not sure the kit even comes with the washers. I assumed I would be expected to reuse the original washers. And even if it comes with washers, I'm not sure how I would tell if it's the old part or not. Anyway, I'm all good now.

BillV said:

With regard to the different driven plate thickness, you'll see the same thing on page 3-96 of the service manual. Except there it's the outermost plate vs. next to the outermost in the fiche. I have two guesses regarding what it's about and both relate to pack thickness. One is that there's a target thickness when new and the varying thickness allows you to better reach it. The other is that it allows you to compensate for wear on the drive plates. It's been in the service manual from the beginning so it's not a part update.

P.S. Please measure the plates in the kit when you get it and report back here.

Click to expand...

Aha! It had not clicked in my brain that the T designation on the fiche stood for Thickness.

I feel pretty safe assuming that the complete kit will have the correct plates for the desired overall stack thickness.

But I can definitely measure and report back after I receive the kit.

From what I've read in this thread, I'm pretty stoked to have this much-improved clutch! I have a drill press and plan to do the full Monte.

The 2.3mm is listed on the fiche as stock part for the K1. The 2.0mm and 2.6mm are listed as "OPT" which I translate to optional.

As BillV said, "target thickness" or "pack thickness".

If you look at the clutch stack height and then do some math on the number of plates and thickness you should be able work backwards to calculate the stock driven plate thickness. Think you will end up with 2.3mm on an original OEM pack.

EDIT: Should have said mainly 2.3mm. There could be optional one or two used to make the right height.

petgsxr said:

$105 is pretty good... I think you'll be fine with the kit but I think you'll need to make sure it comes with the new version of the wave washer which I'm sure it does

Click to expand...

Nope. It came with fiber plates, steel plates, 6 clutch springs, and the gasket. No wave or other washers.

BillV said:

P.S. Please measure the plates in the kit when you get it and report back here. It's my impression that the kit includes the springs, drive plates, driven plates, and the cover gasket.

Click to expand...

It came with:

1 x 21442-41G00 fiber plate, which measures 0.112" (which is 2.84mm) according to my Dillon calipers
9 x 21441-36F10 fiber plates, one of which measures 0.112" (didn't measure the others)
1 x 21451-41G10 steel plate, which measures 0.078"
1 x 21451-41G20 steel plate, which measures 0.101"
9 x 21451-41G00 steel plates, one of which measures 0.090"

If the install goes anything other than totally normally, I will definitely report back with an update.

How about the thicknesses of the steel plates?

This thread is just what I was looking for. My K5 (5300 miles) has been out of circulation for a few years but damn! Just took it for a ride and the clutch growls/buzzes like crazy! A couple of questions though before jumping into the mod. 1-Does this problem cause damage to the clutch and if so what unique things should I be looking for during disassembly? 2-What oil are guys having the best luck with after the mod? and 3-Is there someone local who can punch me in the head for keeping this thing in storage for so long? :bitchslap Forgot what a rocket it is!

Wanted to add my piece to this.

I ride a K6 and originally the clutch would grab sometimes when coming out of first with the RPMs up a bit. I had seen this thread but then ran into a guy selling a Brocks 1 piece designed to replace the back-torque limiter. He didn't have the Brocks springs so I bought those new. Put it all in and bam, worked great, so I thought. Took it on a 4 hour ride of of town and it got to where if I came off of it too fast, it would grab. I had a feather the clutch until I got back home a few days later.

Took it apart and found some of the fibers had no oil on them, thus why it was grabbing. So I drilled out the 3 additional holes and out it back together and it has been good so far.

xenalmorph said:

3-Is there someone local who can punch me in the head for keeping this thing in storage for so long?

Click to expand...

Where are you located? :bitchslap :lol

My 06 Gsxr 1000 does not chatter but the clutch is done... I plan to tear it apart and do this mod as soon as I get the new clutch parts. Quick question though should I do the Brock's ultra lite clutch mod at the same time? I want to be sure I replace everything that will benefit my 60' and et under this case so I don't miss anything... So far I plan to drill the 3 holes, replace washer, install oem clutch kit, and Brock's ultra lite clutch mod. Is there anything I should add or remove from this list? (Clutch springs, spring holders, ect). I appreciate any feedback. Thanks!

Will this fix a lot of slop in the clutch? Because whenever I shift, I can feel the entire clutch assembly click forward. And in first gear, if I take off, the bike bogs down no matter how high I bring the RPMs. And yes I am an experienced rider, so it's not personal error. If anyone could get back, it would be much appreciated unk

im confused as to where exactly we install the 750 clutch washer....? and is all else were doing is drilling holes or making them bigger?

SPL170db said:

Confused about what? It goes exactly where #14 is here. Drilling the holes is optional, honestly you really don't even need to do it.

Click to expand...

Ohh gotcha thanks


Sent from Motorcycle.com App