Hayabusa Clutch Cushion Kit Installation
Contents
1. S13 CCK 02 S13 CCK LC INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT uo usri Yin Guim oac wWODGUDOJHIOJQ MMM ONI S3SRIMd831N3 NOSGIAVG X39088 FINYFITOL HID ELS adavaNnvis pasunbay J DBuo ON sjs0g MIA apis paaoway 9 sunds 7944019 jO snoiasd Jo 4291 9 AIS y MI uoJ j paaoway uizi o wwo s Z oN 0 4 saqiy uly p JO p abdg BOIS Ay juawsao0jg buds 1099S IAW paaoway 9 SqAGIT 492005 ANDI 4 POW YI S MIOHA aOIS TINT payjddns p QH 3ag Suds ajdung QNG nD H 210925 Of ON MIIA UOJ ojqg Jnss Jdqg payddns Z OH3 309 buds u JO ANG AD H DOJ1x3 eesbuuds S MIOYG yim ssa20dS POW 491019 S 9OY HOISU LON Cee ynses pinod buwuds ay JO Ajyiqodod poo ay o abowog puiq 1102 yybray pyos o SSAJDWOD O PAMO IO 2q AIAIN snw s6uuds S 4D0NG HON 102905 S13 CCK 02 S13 CCK LC INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT 0313133d5 Gmp uoiysng 0081 ISIA IHID SS3NA Dimana lo aga 3903 ONY SHINUDI d vHS Vv xv358 ee OOO PAON a 930 1 F 20 AII EIS Nd 308 2060 uoiysng 49ND sng 2002 00 F Guimouq 1o1u u ddns Slo WODY BUID0UHIO UA MMM 0E0 03141334S 3SIABIHLD SSIMNN ONI SASINdUALNA NOSGIAVG NIONA 33NSN23 111 M aps DIS INJ 2 025 0 OU A IA luoJj OlJbZ 1bbl2Z Pld ZnS uig O wwgg s L ON Dld 1 q J Y21414 JO 260g MII ELS 29qtunN2. in the lever 8 While pressing the ball down towards the lever pull the clutch lever away from the bar and push the stock cam towards the exit direction as shown in the drawing on page 2 Have someone hold the bike bars in place Caution The stock Spring Loaded Ball will exit the pocket as you perform this motion WEAR SAFETY GLASSES The ball will likely spring shoot out and roll away never to be seen again This is why we included a spare ball with your BROCK S Lever Cam You may use either ball during assembly 9 After the stock lever cam ball and spring are removed set the ball and spring aside for a moment Dry assembly the BROCK S Lever Cam by aligning position number 6 with the arrow and sliding the BROCK S Lever Cam into position while holding the lever away from the bar 10 Remove the BROCK S Lever Cam and re install the spring in to the pocket in the lever Place the ball on top of the spring and hold it in place as you perform the action described above The BROCK S Lever Cam was designed to install far easier than the stock cam was to extract The spring and ball hold the BROCK S Lever Cam in place just like the stock lever cam 11 DANGER DO NOT ATTEMPT TO DRIVE YOUR MOTORCYCLE UNLESS YOU ARE POSITIVE THAT THE BROCK S LEVER CAM IS PROPERLY I NSTALLED Doing so could lead to a potentially dangerous situation 12 Check the BROCK S Lever Cam for proper operation by turning it to different positions as you feel
3. the click 13 Set the BROCK S Lever Cam to the desired position for you application as described in the introduction S13 CCK 02 513 CCK LC INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT Buy WODUDAD 43141334S Ea a E _ 26 Tw want a930 1 21 233932 81S 1d 304 Gag Uu01 01104 SU 0AOWA Y WO waaay osnqo oH lt 3131934 uo2 6ui30J2320JQq ana IRID SSW LNG NOSGIAVG 309048 JINY IF DL YO IMS 4 9J0S ae F P uonp3o pasisap ay 0 1 sn py Z JO Z 9abdg IDG S PUDY BY SP4OMO JAA y buyjnd Ajybys ayiym 9 uoljisod o un uonisod jo jjo sn fpo oj uonisod y20 D S WOD 13497 70g a4 UO uonisog HON 0199dS UOND O SU OAOWaxy UID 19137 apolg o 9V X paying 0g p poo7 buuds
4. 1404 JOG SUONINJISU Ajquiassy y uonusn2 yI nN Q ay Jo abod uo pequosap so Ajqwasso iy uoiysng ulbag S lgpouu 002 6661 snomn sd ay o Aqwasso YANI ZOOZ ay Sjsaauod Siy OlJb2Z lItbblZ saquinu od 1yNzNS a 0 0 4aqiy 4214 pasojqua ajbuis y YIM S jUaUOdWOD Ju S Y aD0 day pasinbas sabuoj ou as0 sjiod asay buuds J ppnf puo saysoy sog aj0y absoj Ym 0 d saqiy J214 SOwJ uu BY aAOWAY OSNGOAOH 002 2002 asog JOYSOM M p S bunds 1995 IPF apos o jou m juos seppnr pasinbay JON s jiod jojay I913W Z puo oH GI BJO UMA O J 12141 xx ISJIJ SdILS FISFIHL WYOJYJd lt u w jddnS DSNqD DH L0 20 y INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT S13 CCK 02 S13 CCK LC BROCK DAVIDSON ENTERPRISES INC www brockracing com The Brock s Performance Productse Hayabusa Lever Cam Kit J ockey Inspired Clutch Adjustment for the Busa Introduction Congratulations on your purchase of the Brock s Performance Productse 1999 2008 Suzuki GSX1300R Hayabusa Lever Cam Kit BROCK S Part Number S13 CCK LC The Lever Cam is a multi purpose adjustment device which allows the stock clutch lever to be fine tuned for the needs of the Sportbike Drag Racer As the clutch wears the distance in which the clutch engages becomes farther away from the handle bar Most riders have more launch control with the lever nearer to the bar since your
5. INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT S13 CCK 02 S13 CCK LC BROCK DAVIDSON ENTERPRISES INC The Brock s Performance Productse Hayabusa Clutch Cushion Kit Finally consistently smooth clutch operation from a Busa I Introduction Congratulations on your purchase of the Brock s Performance Products 1999 2001 Suzuki GSX1300R Hayabusa Clutch Cushion TM Kit Part Number S13 CCK 02 Special note The 2002 07 Hayabusa s requires part number S13 CCK 02 for proper operation The purpose of this kit is to remove the chatter and grab associated with normal clutch component assembly wear caused by drag race launches insertion of heavy duty clutch springs or the addition of a lock up clutch unit The Hayabusa has developed a notorious reputation for an unpredictable clutch action This undesirable effect is compounded in high torque applications such as in increased displacement engines This kit produces a smooth clutch actuation and provides excellent feedback to the rider even as the clutch wears and becomes heat dried from repeated launches The days of soaking your clutches before heading to the track are over Brock s Clutch Cushion Kit is compatible with aftermarket lock ups billet outer baskets and inner hubs Adaptor kit Part number S13 CCK MTC is designed for use with these components and S13 CCK Caution must be taken to assure clutch spring coil bind Brock s HD and EHD clutch spring installed heigh
6. ION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT S13 CCK 02 S13 CCK LC BROCK DAVIDSON ENTERPRISES INC www brockracing com Installation 1 Read the Introduction on page 1 and study the enclosed drawings on pages 3 and 4 If you do not understand these please seek assistance You may also wish to check our Information Forum at www brockracing com 2 A complete listing of Brock Davidson Enterprises Inc warranty information and policies should be viewed on our web site www brockracing com policies 3 There are no special tools required to install the Brock s Clutch Cushion Kit Standard tools to remove install stock clutches are required It is wise to place an object between your clutch lever and the handle bar to block accidental actuation while installing this kit It can be as simple as a paint can lid and some tape Re bleeding the clutch slave assembly is NOT a pleasurable task 4 Begin by performing the inspections outlined on page 1 If your existing sprocket cover is cracked the Cushion Kit WILL finish it off Inspect the cover before installation Lock up users will also destroy the cover unless a suitable brace is installed 5 If all components are in acceptable condition reassemble the outer basket Inner Clutch Hub and Clutch Mod Assembly Tighten the Clutch Sleeve Hub Nut to the appropriate torque specification 68 5 lb ft 95 Nm Warning If you are not skilled in replacing these parts PLEASE consult you Clutch Mod I
7. d new the Busa comes with several loose springs the baskets are usually fine for a while assuming the notches can be filed smooth If all of the springs are loose in the pockets the basket is damaged Rebuild or replace it The Clutch Cushion Kit was designed to perform best with the stock hydraulic clutch system with Brock s Lever Cam and Genuine Suzuki steel and friction plates Frictions and steels are available through your authorized Suzuki Dealer Part numbers will vary depending on the year of the bike Aftermarket Clutches are not recommended If you plan to use your existing clutch you will have an extra thin friction plate left over Keep this plate for use at a later time We rarely install a complete new clutch assembly all at once unless a major clutch failure has occurred or definite slippage is noticed Instead the clutch is regularly inspected for wear and or damage If any friction Drive plates show signs of glazing or smearing of the pads or they measures less than the service limit Standard No 1 2 92 3 08mm 0 115 0 121 in or No 2 3 72 3 88mm 0 146 0 153 in we replace only those plates The same is true of the steel plates if they are warped or galled due to heat The Driven plate distortion limit No 1 and No 2 service limit is 0 10mm or 0 004 inches measured on a surface plate with a feeler gage At the track we simply stack all of the steel plates together and look for light between the plates replacing only the p
8. ever Cam as described in the Lever Cam instructions Do not attempt to use the Hayabusa Clutch Cushion kit without the Lever Cam installed Clutch drag or creep may occur leading to a potentially dangerous situation or burned clutch plates 15 FYI Typically we set the Lever Cam to the 2 position and perform several dry hops to seat the Clutch Mod assembly We then adjust the Lever Cam to rider s desired position See special note on the lever cam instructions to adjust from position 1 Page 2 of 5 S13 CCK 02 S13 CCK LC INI SASIYdYALNA NOSGIAVG X32088 205 JOJ WOYBuUD0uHDOJO mum 3INV 37DL 19101 Z Z oN uQ 0ld J Q J HID ELS 260g I anbiy aas juawas0jg buds a 0 d INSS JJ Iquwassy pow 120 S Ajquiassy saysNg YANNI A S YNNI 1203S JOYSOM OQ 19191 Z L ON 42141 Dld 49Q14 MBI OPIS yonuow 1yNZNS aas 211 29 JOU JUaWaIO g xow 329121 Z uly Z 1910 6 lOIJ4_ 991S pa rowas 0 p awos p JO bog 05S O JON M qwassy 49M p yddns uo sno 5o S jong payddns uly uoiusn 1201S I4Snp gny YD Jauut Paj O Suj Ajsadosg JUIWIIO g buosy4 d1r7 9pP S yjoows QNH YNNI sauU INSTALLATION INSTRUCTIONS 1999 2001 HAYABUSA CLUTCH CUSHION KIT ay JO BuoO j JO N u uo 6unsas puo pasa jua9 aq Isnw buy uvoiysng jo OPIS PasSsaray 9 ON eINIWNIIWW YIdONd YOS mea YVID dWNd WO MIFHD papunoy
9. fingers have more strength closer to a fist than they do straight out The stock lever cam has adjustment positions but they are usually not enough after the clutch has been subjected to multiple drag style launches The BROCK S Lever Cam now has six positions Positions six five and four are dedicated to positioning the lever closer to the bar than the stock unit will allow From small hands to a well worn clutch these positions work the best Positions three two and one are for use with the BROCK S Hayabusa Clutch Cushion Kit TM BROCK S Part Number S13 CCK or S13 CCK 02 or for riders with exceptionally large hands If your riding style dictates that you hold on to the bars with several fingers under the clutch lever any BROCK S Lever Cam position which allows the bike to be staged without moving should be chosen If the lever cam does not stay in the desired position the clutch lever may be worn out or damaged replace the lever assembly Suzuki Part number 57500 24F00 Caution Bumed clutch plates or a damaged Clutch Cushion may result if the rider holds the bike in place while creeping or dragging Special Note When operating in positions six or five or if the bike is fitted with oversized handle grips you may notice the engine not starting Do not be alarmed The Hayabusa is fitted with a safety switch which does not allow the bike to start unless the lever is pulled in Usually a tighter grip on the lever is enough to engage the
10. lates that are warped It is typical for the steel plates to turn blue and show hot spots Do not be alarmed A no bar rider MUST slip the clutch off of the line to prevent wheelies or tire spin this is what generates the discoloration The weight on the lock up or the additional spring pressure we provide in the kit take over after the clutch is fully allowed to engage by the rider preventing excessive clutch slippage during the run Some slippage is desired during the run to prevent excessive tire spin or wheelies during the run and after the gearshifts Finally the specifications outlined in these instructions were developed using several different engine configurations and varying horsepower outputs Chassis set up and gearing naturally aspirated and artificially induced horsepower in addition to rider style affect every application differently We have found that these specifications work the best as a starting point in a majority of situations Some riders may wish to slightly adjust their riding style with the cushion The bike can now be launched at lower rpms and the clutch can be fully released sooner while the throttle is gradually applied to full lock before the 1 2 shift A smooth style is the key to long clutch and cushion life as well as quicker elapsed times and higher MPH s due to less heat being applied to the clutch There is no need to fight the bike Let it do the work and the results will show immediately Page 1 of 5 INSTALLAT
11. nstructions and Suzuki Manual Engine damage may result if the Clutch Mod is not assembled correctly or the Oil Pump Gears are not aligned properly 6 Position the small lip on the recessed counter bored side of the Cushion Ring over the rear flange of the Inner Clutch Hub DO NOT INSERT A STEEL PLATE INTO THE ALUMINUM CUSHION RING See Lip Flange placement Note and Arrows on the Clutch Assembly drawing on page 3 The installer will see the smooth side of the cushion ring when properly mounted The Cushion ring must be CENTERED on the rear flange of the Inner Clutch Hub NOT resting on the splines of the Inner Clutch Hub or tilted in any way 7 Install the Dual Stage Cushion over the teeth of the Inner Clutch Hub and into the center hole of the Cushion Ring 8 Position a STEEL plate with the rounded edge see note 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 rounded edge is small feel for it with your fingers FYI There are a total of 9 steels and 9 Fibers used 7 thin fibers No 1 3 0mm 0 12in and 2 thick fibers No 2 3 8mm 0 15in thick A detailed drawing is included in your Suzuki Manual Specia Note We usually apply a SMALL amount of oil to the friction plates before installation There is no need to over oil the plates 9 Install a Thick No 1 Fiber plate then another Steel this time with the rounded edge facing TOWARD
12. switch In some cases it may need to be adjusted The switch is located directly in front of the Clutch master cylinder reservoir on the left handle bar it has two black yellow wires leading in to it A small Phillips head screw holds the switch in place Loosen the screw slightly push the switch towards the clutch lever and re tighten the screw For details see the enclosed drawing on page 2 Installation 1 Read the Introduction above and study the drawing on page 2 If you do not understand these please seek assistance You may also wish to check our Information Forum at www brockracing com 2 A complete listing of Brock Davidson Enterprises warranty and policies should be viewed on our web site www brockracing com policies 3 The BROCK S Lever Cam can be easily installed with the clutch lever mounted on the bike BROCK S does not recommend removing the lever from the bike for this operation problems upon reassembly could occur 4 Place a large towel or blanket under the clutch side of the bike This is to catch the spring loaded ball DO IT Or the frustration of this assembly can become world class 5 The stock lever cam is held in place by a Spring Loaded Ball as shown in the drawing on page 2 6 Adjust the stock lever cam to the number 4 position 7 Insert a dulled X Acto blade or similar piece of thin metal between the stock lever cam and lever between positions 2 and 3 to press the ball back in to the pocket
13. t of 790 inches minimum does not occur if any components are used which are not specifically outlined in these instructions Damage to the sprocket cover which houses the hydraulic clutch slave cylinder is likely if the springs bind This kit as supplied is designed for use with stock components utilizing the Brock s Clutch Mod Part Number S13 CM NOCORE and supplied Lever Cam Part Number S13 CCK LC This product is intended for racetrack use Considerable lever pressure is noticed after installation We recommend a Genuine Suzuki Service Manual Suzuki Part Number 99500 39180 03E for installation and reference purposes The Clutch Cushion Kit is not designed to compensate for failing clutch components Inspect your clutch hub outer basket and backing plate springs before installation of this kit The clutch hub develops notches in the areas where the steel plates drive it Slide a steel clutch plate over the hub preload the plate to the left while holding the hub stationary and attempt to slide the steel in and out If resistance is felt over any notches file them smooth or replace the clutch hub Suzuki Part Number 21410 24F00 Perform the same test with the outer basket and a friction plate preloading the friction to the right File the notches or replace the outer basket Suzuki Part Number 21200 24830 Also inspect the outer basket backing plate springs for sag Shake the basket If al least 1 spring does not rattle FYI Even purchase
14. the engine The remaining Steels will be positioned in this configuration Continue the installation Steel Thin No 2 Fiber until you finish with a Thick No 1 Fiber Be sure to insert the outermost Thick No 1 Fiber drive plate claws in to other slits of the outer basket A diagram is shown in your Suzuki manual 10 Install the Clutch Pusher Assembly 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 Assembly toward the engine with your thumb and index finger The Pressure Plate should now align and seat correctly 11 Position the supplied springs in the pockets as shown in Figure 1 on page 4 Four of the springs are heavy duty HD Purple and two of the springs are extra heavy duty EHD Green Compare the springs to the scale drawing These springs are specifically designed for use with the Clutch Cushion The Spacers supplied with your Clutch Mod are NO Longer Required 12 Remove your lever block Check the clutch for proper operation by visually inspecting the Pressure Plate movement as you manually cycle the clutch lever 13 Check Figure 2 on page 4 to verify the correct No Longer Required parts remain Replace the Clutch Cover 6 5 9 5 Ib ft and remaining body work 14 Install and adjust L
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