SuzukiSavage.com - R&R Cylinder Head with Tech Assist

ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #165 - 12/22/23 at 08:47:08 Transmission shaft looks good. Threads look good. Anything I'm not seeing?
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #166 - 12/22/23 at 08:48:03 Oil pump gear and dowel in place. Seems good to me.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #167 - 12/22/23 at 08:48:55 Clutch Hub with Washer.
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ThumperPaul

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Re: R&R Cylinder Head with Tech Assist
Reply #168 - 12/22/23 at 09:01:16

Clutch Pack on the Bench. Yay. Now time to remove the springs, discs, and plates and start measuring, inspecting, and soaking and cleaning up the friction discs in fresh oil with a nylon brush.

I'm dismissing some suggestions to clean with gas, kerosene, brake parts cleaner, simply green, dish soap and water, drying, baking in the sun, sanding, etc, etc, etc.

It's a wet clutch that likes fresh Rotella T4 oil and needs to create friction. Solvents, water, soap, and possibly removing material and thinning the discs doesn't compute in my brain. If I see some bad glazing, I might hit those spots with a little buffing of 600 grit automotive sand paper.

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ThumperPaul

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Re: R&R Cylinder Head with Tech Assist
Reply #169 - 12/22/23 at 10:06:21

Clutch pack in hand. There are 2 clutch plates side-by-side. Shouldn't one of those clutch plates go next to the thicker 1st Number 1 fatter friction disc?

#1 fat friction disc, plate, friction disc2, plate, friction disc2, plate, friction disc2, plate, and so on....until you end with a friction disc2 against the pressure plate. Right?

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Clutch_Pack_Stack_Order.jpeg

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: R&R Cylinder Head with Tech Assist Reply #170 - 12/22/23 at 10:13:53 correct alternate plates with disks
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #171 - 12/22/23 at 10:17:41 All the plates look about like this. They seem alright to me - not toasted or bluing. They are reading 1.4mm thick on my cheap caliper (no spec on these).
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: R&R Cylinder Head with Tech Assist Reply #172 - 12/22/23 at 10:19:17 2 steel plates adjacent to each other.....and 2 fiber discs adjacent to each other - That aint' right!
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Re: R&R Cylinder Head with Tech Assist
Reply #173 - 12/22/23 at 10:29:56

I'm not going to post photos of all the #2 fiber disc measurements. They are all reading right at 2.9mm (again with my cheap caliper and squeezing tight). A generous reading of 2.9-3.0mm was observed across all #2 fiber discs.

Standard is 2.92-3.08mm. Wear limit is 2.62mm (0.103 in).

I didn't measure every friction disc claw. They all seem to be about 15.8mm. They ain't going nowhere.

I feel pretty good about these.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #174 - 12/22/23 at 10:34:46 The No1 friction disc measured 3.4mm. Standard is 3.45-3.55mm. Wear limit is 3.15mm. I feel good about it. Any observations about my clutch pack aside from 2 clutch plates next to each other instead of alternating? Do they look like stock Suzuki OEM parts? I think so...
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #175 - 12/22/23 at 10:51:01 Thanks Verslagen and Dave! Even a knob like me knew that didn’t look right! It hurt my OCD. Verslagen- Holler at me about the CCT.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: R&R Cylinder Head with Tech Assist Reply #176 - 12/22/23 at 10:51:24 Show us a photo of a fiber disc plate with the oil wiped off.
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Re: R&R Cylinder Head with Tech Assist
Reply #177 - 12/22/23 at 11:04:24

Well look at you. Bet you're feelin pretty sassy right about now. Good job.

Yes, like Dave asked, please take clear pictures of the friction material, just like you did with the steel plate. Also, how was the wave-washer assembly? Was it installed correctly? Can you take pics of that too.

I have a few comments that are sort of getting ahead, but it will give you something to think about while you are cleaning clutch plates.

It's great that you stored the CCT bolt back in the rear chain guide. It's a special shoulder bolt, and it's small. Easy to lose. I suggest you also store your clutch thrust washer and the spacer on the input shaft. They will help protect the shaft, and help prevent getting the washers mixed up (previously mentioned). Store them on the shaft like this.

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Input_Shaft_002.jpg

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: R&R Cylinder Head with Tech Assist Reply #178 - 12/22/23 at 11:06:40 That special CCT bolt threads into a RivNut on the rear chain guide. See how there is a nut attached to the guide.
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Re: R&R Cylinder Head with Tech Assist
Reply #179 - 12/22/23 at 11:12:14

When you tighten or loosen the special shoulder bolt, you want to hold the nut with a wrench so as not to break the nut loose from the guide. Also, when you reinstall the CCT, I suggest you make sure the threads on the bolt and the nut are clean and oil free, then apply Loctite. The manual doesn't specify thread locker, but the ramifications of this bolt coming loose warrant thread locker. I personally use the red stuff on this one, but I suspect blue would be sufficient.

When removing or installing, hold the nut with a wrench, like this.

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