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Old 10-27-2008, 06:48 PM   #1
notstock22
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how to replace clutch on 05 gsxr 750

as the title says i need to replace clutch on my gsxr but have no clue how is someone could lead me in the right direction i would be greatful
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Old 10-27-2008, 06:50 PM   #2
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Old 10-27-2008, 06:55 PM   #3
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ummm

not to hard , well not on the 2000 not sure about the newer bikes! hit up patrick at Motorcycles Unlimited or just get a service manuel!

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Old 10-27-2008, 07:07 PM   #4
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Old 10-28-2008, 12:50 AM   #5
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If you REALLY need a new clutch, read below. Is it really slipping when the bike is in gear? Is it adjusted to have a small amount of free play at the lever?

Tools: 8mm and 10 mm ratchets, flat head screw driver.

Either lay the bike on it's left side on a soft surface, or drain your oil first.

Loosen all 8mm headed bolts on the clutch cover (oil fill / level window cover). Note two bolts are longer and have washers these go on the front two holes. All else are same length. Two have wire clamps to hold engine wiring. Take these out and set aside. Clear the two wires and remove cover. Best bet is to leave all bolts in the cover and set it face down on a clean surface.

Remove slowly and carefully, prying on the provided pry spot, unless you want to buy a new gasket. You now have clear access to the clutch inside.

To see how it works, pull the lever in and out while watching the assembly. It is important to look first, then wrench so you know how it should look when done. Remove the 5 10mm bolts with washers holding the clutch springs tight. These are little bolts with washers that when tight keep the spring pressure on the clutch to keep the plates smashed together. NOTE THE AMOUNT OF PRESSURE IT TAKES TO BREAK THEM LOOSE. REMEMBER HOW MUCH SO YOU CAN TIGHTEN BUT NOT OVERTIGHTEN THEM WHEN REINSTALLING!!! I used 50% of my index finger strength on a six inch ratchet, or maybe 10-15 foot pounds of force. Once out, the rest of the clutch innards are free to slide out without tools.

Now the clutch can be dissassembled. Take carefull notice of the location of the washer, throw out bearing, and plunger under the outer cap that applies the spring pressure. The order, from outside to inside, is: Outer Cap, flat washer, throw out bearing, plunger.

There are 19 plates under the outer cap. 10 friction (with small friction pucks) and 9 steel plates. Order is: Outer Cap / friction 1 / steel plate / friction 2 / steel / friction 3 / steel / friction 4 / steel / friction 5 / steel / friction 6 / steel/ friction 7 / steel / friction 8 / steel / friction 9 /clutch hub. It's self explanatory once you get in there.

Pull out all the plates. Replace friction if on a budget, friction and steel if you choose. Install plunger, bearing, washer, then outer cap. Install 5 springs and bolts. Tighten with same pressure used to remove. Be careful, these little bolts shear easily if manhandled.

BEFORE INSTALLING CASE COVER: Check operation of clutch lever. Adjust play.

Install cover. Check oil level if any is lost. Best to change the oil now if your clutch has been slipping. Check for leaks. Check clutch operation while on the stand, before riding. Adjust freeplay at lever.

Just did this to my 04' 750 on Thursday. It took about an hour and a half including an oil and filter change and pulling the "new" clutch from a parts motor. Just a clutch could be done in 30 minutes no problem.

Check Ron Ayers motorsports online for an expanded diagram.
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Old 10-28-2008, 11:03 PM   #6
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Make sure you get a new gaskit for the clutch cover...some people might tell you to just use suzuki bond but the gaskits are so much cleaner.
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Old 10-28-2008, 11:20 PM   #7
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you need to let the friction plates soak in oil before you install them, also check the clutch basket for wear, let me know if you need any help
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Old 12-09-2008, 10:34 PM   #8
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thanks alot i am goin to call Motorcycles Unlimited tomorrow and price clutch kit and gaskets but bike is already up on stands and ready for new parts...had to put it up cuz now i am loosing 5th gear hmm but gotta get it ready for summer thanks for all the tips and i will pm if i have any other ?s
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Old 12-09-2008, 11:56 PM   #9
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make sure you inspect the basket and cover plate etc for any wear. i did a clutch recently that the basket was notched from each friction disc and the steel discs were blued badly....it was not a cheap job!
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Old 12-10-2008, 12:11 AM   #10
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Quote:
Originally Posted by notstock22 View Post
thanks alot i am goin to call Motorcycles Unlimited tomorrow and price clutch kit and gaskets but bike is already up on stands and ready for new parts...had to put it up cuz now i am loosing 5th gear hmm but gotta get it ready for summer thanks for all the tips and i will pm if i have any other ?s
losing 5th gear?


if it were clutches it would affect all gears, lower gears more so than higher gears....

what is it actually doing?
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Old 01-07-2009, 06:19 PM   #11
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^sorry it took so long to respond but holidays anyways if you still reading this thread um i cant not get the bike in 6th gear cuz it grinds and now 5th gear is slipping...when i am in 5th and say going 50 or so i can open throttle all the way and the bike pulls but rpm's climb way to fast, it kinda feels like the tire is slipping but in 5th gear it not possible. when i am in second and try to clutch it up sometimes the tire slips well that is what it feels like. sorry if this a substandard description
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Old 01-07-2009, 08:36 PM   #12
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the clutches are slipping. Did you check gaps? are the steels worn?

Also, check and make sure your cable isn't holding the basket taught.
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Old 01-07-2009, 11:24 PM   #13
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i actually have not even taken anything apart yet because i was going to order the clutch kit and seals from Motorcycles Unlimited this friday after payday. do you think i should pull the clutch first? i just dont want to do work then have to wait for parts while the whole time i am risking gettin debris inside the clutch area
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Old 01-08-2009, 02:20 PM   #14
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to be 100% sure, pull fibers and mic them, to make sure they are even worn. if you are going to replace them, contact cycle concepts for clutches and steels. They are $155 plus shipping for the set.
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Old 01-09-2009, 04:48 AM   #15
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You say you can't the bike into 6th gear because its grinding. If that is true you have additional problems besides a slipping clutch - most likely bent shift forks.
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Old 02-07-2009, 10:59 PM   #16
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shift forks in the tranny?
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Old 02-07-2009, 11:43 PM   #17
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If you grasped all of what Shadman wrote you are well on your way.

Changing a clutch in a sport bike while not necessarly difficult but does have an element of puzzel to it.

I would recommend that if you can do your own work, buy the service manual for the bike. about $ 100

You will recover this by being able to do a lot of work yourself correctly the first time.

Good Luck
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Old 02-09-2009, 05:48 PM   #18
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^thanks, ya i have the manual and i just waiting on my income tax then i will fix bike, but thinking bout selling it....maybe
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Old 02-09-2009, 10:26 PM   #19
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the manual you need is prolly 25 bucks. I just bought on a few weeks ago. They are sold everywhere on line. They are just like a Chilton for cars. The clutch it self should take less than an hour. I just did my first one a few weeks ago. Easier than you think.
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Old 02-13-2009, 06:11 PM   #20
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ok so the clutch i out and all looks good i am about to mic them to check if they bad or what? i am thinking about pulling the transmission and components to check shift forks
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