K6 1000 cluctch dramas

[Marcus]

I will try an make it as brief as possible, most K5 K6 owners will be aware of this anyway.

My clutch seemed to be OK on the open road and only plays up in city riding.

However it has become harder and harder to do U turns on as riding it just felt wrong.

So I took it to the dealer, they checked a few things out and have the bike there at the moment.

I just spoke with the service manager and he said it does seem to be a problem but will need to order the parts in and book it in for next week.

Has anyone had it done before? Did they replace your clutch packs? Im thinking the plates might be starting to warp as it has a very small shudder.

[dilbee]

yeah theres a problem with some bikes. In some cases theres been replacement of the whole clutch plates. But by the sounds of it they replace a washer or a spring/springs from a 750.
posted off gsxr.com for ya to look at.
There is a know problem with the clutch on the 05-06 model that Suzuki is aware of. Make enough noise and they will replace it under warrenty.

I was the second one in Canada to have it fixed. My problem was that the clutch plates would stick. There was a resistance when I pulled inthe clutch and on occasion a audible clapping sound as they released. From what I am told they replaced some of the parts with some 750 clutch parts and it seems to have fixed it. I still get some resistace when clutching on occasion but no more noise.

[dilbee]

This is another post from someone on gsxr.com

There has been a lot of talk about the K5/6 clutch and it's adjustment etc.

Well I have a K5 clutch in my K2 and I've been doing some testing and adjusting and come up with a pretty sweet setup.

Keep in mind all this testing is done on the road with all kinds of riding in mind.

Where do I start ?

The stock clutch runs very dry.

The first thing I did was to add the 3 extra holes to the clutch basket.

The next thing was to grease the ramps on the lifters

The stock clutch springs are a little soft. They let the clutch slip a little too easy and if you make a bit more power (180 plus at the back) then they can even let the clutch slip under hard acceleration.

I changed the stock clutch springs for Barnett ones. I believe they are approx 15% stiffer. They feel about 15% stiffer on the clutch lever too.

I also noticed while I was at it that the top of the clutch spring is not held straight in it's hole so it flings out and rubs on the clutch hat. I had some custom washers made to retain them straight. ( made by - mperacingonline - with some www. and a .com)

The stock clutch comes with 2 "reaction washers". These are the cone sahped ones with all the fingers on them. Each stock spring provides 225N of spring pressure.
The stock setup is therefore 450N. I read soemwhere that Yoshimura use more like 675N. This is 3 stock springs. (there is a Yoshi kit available with 150N and 300N springs for more tunning)
So I bought a 3rd reaction spring and fitted it too.

Then I adjusted the lift pins , turn them in till they bottom, turn them out 2 and 1/4 turns and lock up the nut.

On the road then the clutch is a little heavier than stock but not a heavy clutch. When you change down gears it's still really smooth when you let the clutch out and the slipper still works but with some engine braking.

It will still never lock the back wheel and is silky smooth.

The only other adjustment to watch is the push piece. You need to make sure there is some room for it to move before it pushes the clutch hat or it can keep the clutch partly unloaded.

This is the adjustment most people are concentrating on but if you don't get the lift pins right you could wear the clutch out pretty quick and have it bottoming on the push piece again in no time.

I guess what I'm saying is... it's a package deal.

Get the whole package right and it's a really sweet setup.

[MadHatter]

Interesting information.
Every K5/6 i've tested had a little bit of a shudder letting the clutch out at low revs.. nothing terrible though I have heard of it getting worse.

[Marcus]

Yeah it seems fine just doing a few runs, my problem seems to multiply when the engine is hot and you come across a few sets of lights

[dilbee]

Thats easy fixed then, just dont stop at lights. haha

[Marcus]

Got the bike back, they said they couldnt replicate the problem.

Well with 5klm on the bike I dont think you could!

I specifically told them its when the engine was sitting in traffic and a few cycles to over 100deg, take off from 4-5 sets of lights in a row and bang theres ya problem!

Anyway the manager said he would speak with Suzuki about it and to call back wednesday...

[jasonbw]

print this thread!!!

[dilbee]

if its any help ill go down and speak to the guys at my old work at westerns and see what they say. Its not what ya know sometimes but who. Cant promise anything but ill see what i can do for ya.

[Johnny]

Got the bike back, they said they couldnt replicate the problem.

Well with 5klm on the bike I dont think you could!

I specifically told them its when the engine was sitting in traffic and a few cycles to over 100deg, take off from 4-5 sets of lights in a row and bang theres ya problem!

Anyway the manager said he would speak with Suzuki about it and to call back wednesday...
Now go back, tell them to remove hand from dick for just a moment, and tell them its a known problem in the K5 /K6 thous, not in all but a percentage in. While their hand is away from dick for the moment, TELL them to call in for the suzuki warranty to approve and send part. Dont take anything else for an answer, matter of fact its not a question when your telling them, so all you want to know is when..!

It only takes a washer of the 750s clutch to fix it, and from memory its like a $20 part and takes them an hr or two at the most, which you obviously dont pay for as the warranty does pay for it, meaning its an admitted problem

I know, Ive been through the same thing with my K6, have mentioned it here even, somewhere. And yes, the washer does the trick !

Manager is either going to apply for approval of warranty ( which is what you want ), or just trying to brush you off and buy time. Dont let them fool you with that.

[aussiegixxxr]

got the same problem,
in the clutch basket there are 3 predrilled holes, Just drill all the way through to allow the oil to flow...
problem fixed..

[Johnny]

got the same problem,
in the clutch basket there are 3 predrilled holes, Just drill all the way through to allow the oil to flow...
problem fixed..

Some scary advice there mate, for one its covered by warranty as it is known problem, so why would you do that.

I agree though, it would solve the problem, clutch problem anway. It is a wet clutch so any metal shavings possibly left behind would move the problem elsewhere and be much worse and costlier than a $20 washer :)

[Kat00]

its a known problem in the K5 /K6 thous, not in all but a percentage in.


That is exactly right.

Clutch adjustment is critical with these bikes.

Download the manual from here http://nswrats.com/manuals/
I just PMed you the user name and password.

And try this, the manual says to do this every 6000K`s but I do mine after every couple of track days and mine has been pretty good.

Go to page 2-16 of the manual and follow the instructions.

Failing that, Ya might have to do what Dilbee recommended.

[Marcus]

I didnt get the impression he was brushing me off, he said to me on the phone its a problem on some bikes. He also said he had to speak to Suzuki to get approval.. Even though they couldnt replicate it. I sort of understand how warranty works and why he has to get back to me?

There is a thread on gixxer.com with all the details/part numbers but I dont think Suzuki actually drill the hole in the basket. It has specific instructions on how/where to drill and cleaning it. If they approve warranty, I might print it out and give it to them to see what exactly they do.

Kat00 I will check it out.

Dilbee I will keep it in mind as plan b. Plan c will be doing it myself.

The clutch will also groan and shudder on quick take off's which I found out yesterday. Not launching it but riding the clutch for a split second and releasing it quickly with a bit of throttle.

[Turtle]

I've got a couple of mates who had probs on their k5/k6 k's and it was fixed (by the shop) on warranty, it was just a washer, apparently it slightly spacers out the basket (i think.) They noticed slipping on hard launches...

Turtle.

[aussiegixxxr]

Yeh, its a warrenty fix but warrenty is usually a stuff around, any half decent bike mechanic would of had it before. just ring around if you dont want warrenty claim hassle or whatever.

Launch in 2nd if it bothers you.

[j-rad]

That is exactly right.

Clutch adjustment is critical with these bikes.

Download the manual from here http://nswrats.com/manuals/
I just PMed you the user name and password.

And try this, the manual says to do this every 6000K`s but I do mine after every couple of track days and mine has been pretty good.

Go to page 2-16 of the manual and follow the instructions.

Failing that, Ya might have to do what Dilbee recommended.

hi mate, could yuou PM me the password etc for tyhis aswell please?

Just about finished doin the clutch but want to get adjustment right - Haynes manual misses one of the adjustments......

there was another handy thread here somewhere that had images in the thread of the manual too but I can't find it now :confused1:

cheers

[jasonbw]

password is in the first post in the tech thread... see the stickied one at the top..
http://www.nswroadandtrackbikes.com/forums/forumdisplay.php?f=31

[j-rad]

cheers!!

[WET4URacing]

wow you guys want it all. a slipper clutch and routine service on it??????? The big HP K5 i maintain has had 6 clutch packs in its 14k km track life. everytime it starts to shudder when its bein loaded into the van at the end of the day i get a call to order a new set of plates. warranty what the fark is that. 2 to 4 weeks waitin . not for my clients ,

[Turtle]

I think its just a washer they forgot to put in....or its a washer that fixes it

[Bigdog]

You replace a washer with one from a 750 and drill 3 holes opposite the existing ones in the back of the clutch basket to allow more oil flow and a smoother operation.
I have a PDF file of the whole procedure (with pics) if anyone wants to try it themselves. It's very comprehensive and easy to follow.

[2ndclasscitizen]

hi mate, could yuou PM me the password etc for tyhis aswell please?

Just about finished doin the clutch but want to get adjustment right - Haynes manual misses one of the adjustments......

there was another handy thread here somewhere that had images in the thread of the manual too but I can't find it now :confused1:

cheers

I think I need to do that as well, mine feels like it's slipping a tad on hard launches.

[j-rad]

wow you guys want it all. a slipper clutch and routine service on it??????? The big HP K5 i maintain has had 6 clutch packs in its 14k km track life. everytime it starts to shudder when its bein loaded into the van at the end of the day i get a call to order a new set of plates. warranty what the fark is that. 2 to 4 weeks waitin . not for my clients ,

nah my plates where 100% fine - al the issue was that it wasn't getting any oil so got hot. WHen it gets hot it squashes the concaved anti judder spring FLAT and results in the shudder AND a worn out part the 'Clutch PRessure disc - the holes where the springs go through had gone slack due to the flattened judder spring, causing big gouge marks in the wholes - also causing a small build up of FINE metal shavings that also helped block the existing 3 oil holes.....

I paid $82.15 for new parts and drilled the 3new holes - perfection!

Since I don't ride on road and don't really use the slipper clutch the fact it had been dry as a Nuns nasty had no ill affects, had I been launching heaps and/or using slipper I could've had many more issues but that's for me, I'd agree with Wetty and get the plates checked anyways, easy job :ayyy:

[WET4URacing]

Since I don't ride on road and don't really use the slipper clutch the fact it had been dry as a Nuns nasty had no ill affects, had I been launching heaps and/or using slipper I could've had many more issues but that's for me, I'd agree with Wetty and get the plates checked anyways, easy job :ayyy:[/quote]


u say when using slipper????? when do u think u are using the slipper, on launch????????

[j-rad]

:D was out in the shed typing, talking and fixing and obviously not making alot of sense.

When I think of clutch abuse, I think of hard launches from a standstill and using the slipper clutch on the down changes. Since track days don't offer much of an opportunity for race starts and I don't really use the slipper to great affect on the down changes (cause it was dry and grabbing) the problem didn't affect the ride too much but I haven't ridden all that much so wasn't overly concerned (probably should've been yes) but there's a race or 2 I'd like to enter this year so time to sort it out so A) I can start the race and B) start making use of the slipper clutch, on down changes :)

Using the slipper clutch on launch huh :confused1: :lmao:

[WET4URacing]

you wood b suprised how many out there think thats when its used.

[j-rad]

no doubt :D

fired up the bike last night, all adjustments made thanks to the online RATS online manuals, why my Haynes manual is missing one of the steps is interesting but noted for next time....

Bring on June!

[WET4URacing]

what about april and may

[gsx10]

You replace a washer with one from a 750 and drill 3 holes opposite the existing ones in the back of the clutch basket to allow more oil flow and a smoother operation.
I have a PDF file of the whole procedure (with pics) if anyone wants to try it themselves. It's very comprehensive and easy to follow.

can you PM it to me? it's more for interests sake at this stage. clutch seems fine (probably cause I got a new one last year under warranty).

[jasonbw]

what about april and may

:lmao::lmao::lmao::lmao::lmao:

[Bigdog]

can you PM it to me? it's more for interests sake at this stage. clutch seems fine (probably cause I got a new one last year under warranty).

PM me your email address.

[gsx10]

PM me your email address.

just found it on gixxer.com. Is it the same one?

[Bigdog]

just found it on gixxer.com. Is it the same one?

Yep, it's the same one.

[j-rad]

what about april and may

Yeh I wish.....in order to get to a few of these races I'm being careful with cash on track days etc. Accomodation is the killer, having to come up from Canberra and stay the 3-4 nights each time for a few ppl is quite exe.

So no riding in Apr > might do the 24/5 if there's any spots avail but yeh really looking forward to the double start of June which also happens to fall on my birthday !