Brocks Performance Ultra Clutch Mod Kit GSX-R1000 (05-06) - Manual

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Installation Instructions
GSX-R1000 Suzuki (2005-06) Ultra Light Clutch Mod Kit
Brocks Performance Part Number: S1005-CM-ULTRA
This package contains: 1 Brock’s Performance Ultra-Mod
©
1 Brock’s Performance Clutch Pack Spacer
Special Note: The terminology used in these instructions correlate with the Genuine
Suzuki GSX-R1000 Service Manual (PN: 999500-39270-03E).
We recommend the use of this manual for all Brock’s Performance Product
installations and/or maintenance.
More Common (Race) Terminology and useful notes are in parentheses (Example)
A Note before you begin: assembly is in EXACT reverse order of disassembly,
unless otherwise noted.
1. Remove clutch cover. (The fairing need NOT be removed! It is helpful to
remove the rear fairing mounting screw and gently hold the fairing away from
the bike when removing the cover. Use caution-- the cover gasket is re-useable
if undamaged.)
2. Loosen locknuts and remove all three clutch lifter adjusting pin screws/locknuts.
(No longer required.)
3. Loosen and remove all 6 clutch springs and pressure plate.
4. Remove clutch pusher assembly.
5. Loosen clutch sleeve (inner hub) hub nut. (A special tool is available from
Suzuki; we use a glove to hold the inner hub and remove the 30mm nut with
an impact gun.)
6. Remove the nut, spring washer and flat washer.
7. Remove the entire inner hub and drive/driven plates (clutch pack) assembly
from the countershaft (Input Shaft). There is no need to remove the outer
clutch basket. Also Note: When removing the assembly from the input shaft, be
sure to also remove the parts BEHIND the inner hub in order. If the assembly
does not slide out smoothly, then carefully file the stock “stake mark” smooth
without getting shavings into the engine!
8. The thrust washer (flat washer) may remain on the input shaft.
9. Flip the entire clutch assembly over on a flat surface. CAREFULLY remove the
inner hub while allowing the clutch pack to remain intact, including the spring
washer and seat (judder spring and base).