Brocks Performance Shootout Clutch Cushion Kit GSX-R1100/Katana (86-92) - Manual (Page 2)

BROCK DAVIDSON ENTERPRISES, INC.
www.brockracing.com
Installation
1. Read the Introduction on page 1 and study the enclosed assembly drawing on page 3. If you do not
understand these, please seek assistance from somebody who does.
2. Understand that the MTC lock-up clutch is NOT included with the BDE Clutch Cushion Kit.
3. There are no special tools required to install the BDE Clutch Cushion Kit. Standard tools to
remove/install stock clutches are required.
4. Begin by performing the inspections outlined on page 1.
5. If all components are in acceptable condition, reassemble the outer basket and clutch hub. Tighten the
clutch hub nut to the appropriate torque specification (101.5-115.5 lb-ft.)
WARNING: If you are not skilled in replacing these parts, consult your Suzuki manual. IF the oil
pump or alternator is not aligned properly, then SERIOUS and/or expensive damage may result.
6. Position the small lip of the cushion ring over the rear flange of the clutch hub. See lip/flange placement
note on the assembly drawing (page 3.)
7. Install the washer base over the clutch hub into the center hold of the cushion ring.
8. Position the washer, convex point facing AWAY from the engines, over the clutch hub into the center
hold of the cushion ring.
9. Position a STEEL plate, with the rounded edge (see note on page 3) facing away from the engine, over
the clutch hub until it touches the cushion ring. Be careful not to disturb the lip/flange placement. The
steel plates are a punched piece. The rounded edge is small – feel for it with your fingers. FYI: There are
a total of 10 steels and 10 fibers used.
10. Install a FIBER plate, then another STEEL – this time with the rounded edge facing toward the engine.
The remainder of the steels will be positioned in this configuration. Continue the installation (steel – fiber
– steel – fiber – etc…) until you finish with a FIBER.
11. Install the clutch pusher and related components in the proper order. Install the pressure plate, making
sure that the teeth on the pressure plate mesh with the clutch hub. NOTE: The slave cylinders have a
tendency to creep. If the teeth don’t seem to align correctly, remove the pressure plate and press the clutch
pusher toward the engine with your thumb and forefinger. The pressure plate should now align and seat
correctly.
12. Position the supplied springs in the pockets and install the MTC lock-up assembly. Be sure that the
lock-up levers do not bind on the pressure plate as you tighten the 4 screws in a diagonal pattern. There is
no need to add any MTC adjustment shims on the lock-up.
13. Add approximately 8.8 grams total of nut, bolt, and washer to ALL 4 levers on the lock-up. See
assembly drawing on page 3. These are standard steel parts supplied with the MTC lock-up kit.
14. Check the clutch for proper operation by visually inspecting the pressure plate movement as you
manually cycle the clutch lever. Be sure that the pressure plate does not contact the lock-up at full
disengagement of the bind at any point in the travel. NOTE: The clutch lever pressure of this system is
VERY strong. This is how it must be for proper “rider controlled” no-bar operation.
15. Replace the clutch cover (6.5-9.5 lb-ft.) Page 2 of 2