Clutch replacement

[Fireman_on_a_Busa]

I finally got around to replacing my clutch and I have taken pictures of start to finish, but will post them one by one, so there might be some gaps in the sequence.  I noticed that my clutch was slipping because in the higher gears around 8,000 rpms the bike would jump and the catch itself.  I have a total of 32,497 miles on the original clutch.  I have not checked out my work yet, since when I finished up it was dark.  I will keep you posted.  Ok the parts that I used were OEM parts with the exception of the main fibers due to a back-order wait of about 2 months, so I ordered aftermarket.  First thing to do was do drain the oil.  Then remove the right side fairing exposing the clutch cover.

 

[Fireman_on_a_Busa]

Then remove the outer cover to expose the clutch.

 

[Fireman_on_a_Busa]

Opps wrong picture this is the correct one.

 

[Fireman_on_a_Busa]

Remove the bolts and springs on the outside.

 

[Fireman_on_a_Busa]

This will reveal the clutch plates and fibers. Just start removing them.

 

[Fireman_on_a_Busa]

At the last fiber there will be 2 shims / rings. Pay attention to these rings because the only go in one way. One of the washers is flat, and the next on is cone shaped.

 

[Fireman_on_a_Busa]

Replace the fibers and steels in the order that they came out. The last fiber has less surface space that the others, and it is drastically noticible. Reverse the order when placing the fibers back in, and this is what it will look like with new fibers and plates.

 

[Fireman_on_a_Busa]

When you tighten the bolts torque the bolts to to 7Ft Lbs as per the manual. Put the cover back on, paying close attention not to pinch the wire that is located really close to the cover. Tighten the outside bolts, put oil back into the bike, and give her a try. I will ride mine in the morning and check to see how it handles. My question for others here, should I take it easy on the new clutch pads from the start, or ride it normally?

 

[TIMMYDUCK]

Did you soak your fibers in oil ?
If you did, ride normal for 10 or 20 miles and she should be all set I would think.

 

[omslaw]

Nice write-up; thanks!

 

[bigdr]

Congrats..Nice walkthrough..

 

[JINKSTER]

FOAB....those fibers appear "DRY"...did you not soak them in fresh oil for 24 hours before installing them?...as I understand the "soaking in oil for 24 hours" permits the fibers to get fully wicked/saturated with oil...also...did you take a precision "Stack Up Measurement" of the clutchpac (prior to installation) to ensure that the clutchpac w/ aftermarket fibers were within min/max tolerance?....did you check steels for warpage/flatness?..were your hub and baskets showing any "Notching" on the splines/faces?

L8R, Bill.

 

[pitman3321]

i cant beleave that ur local suzuki dealer didnt have fibers in stock, i work at a suzuki dealer and those fibers are a must have item. usually have 2 or 3 sets in stock

 

[hydrabusa]

 

[psycobusa]

you can usually get a set off ebay from that feketorobi guy or something like that. think he's from NJ. usally about 80 a set for fibers and plates.