Hayabusa (99-01) Clutch Cushion Kit P/N
Contents
1. 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 1f 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 plates that are warped It is typical for the steel plat2. p Ip Suj Kueado4d JUBWIIO Y abuol4 a 7 9p S iin gnH YAN 4euu 9u JO 2abuo j 1093 U uo buijse puo pasajuad aq 4SnW bum uonjsn jo apis Dpassa22M JON 6p3 papunoy DOC ID 993223 Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam Kit 99 13 03141330S b JO p 250g 9 D2S Dn j juauisS20 d buudg uols UND Ssa 10 66 9 rc RE Bia R r 4a20dS L 5j Buimoug A jquessy uo28ui204 20 Aq MAM mane POW u2i1n l2 S MOONE ONI SaSINdNH31N3 NOSIAVO X208 JANYA DL 05S INF OavaNvis payddns p xa QH 30g buds ajdung paunbay s96u07 ON S Od Z ambly pa4 owaM 9 sbuudg 21853400448 JO snoi aJd Jo YIINID 4901S M NA 9p S 9199S MPI aip5c oj jou m luojj 2 025 Of 0N M3IA UCL 9 D2S IInd D g asNSS2ldg paiyddns z paAoul8H gH3 3G8 buuds u 19 uzi O wwo s Z oN ng AD H D4 X3 9 0jd 49q j U u 4Sbuuds S 4208B8 UMA sje2ods POW 4919 S 42088 Ilo1SU ION Cee yJnsa pjno2 buuds ay jo Ajyigodod poo ay oj abowog purq 102 jybiay pios oj SS9IGWOD O p mojo 3q YIAIN jsnw sbuudS S 42048 BION 019805 Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam Kit 99 13 DOC ID 993223 BROCK S PERFORMANCE PRODUCTS INC Hayabusa Lever Cam 99 13 Jockey Inspired Clutch Adjustment for the Busa Introduction Congratulations on your purchase of the Brock s Performance Suzuki GSX1300R
3. Hayabusa 99 13 Lever Cam Kit Brock s Part Number 270422 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 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 Brock s Part Number 270396 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 Burned clutch plates or a damaged Clutch Cushion may result if the rider holds the bike in p
4. Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam Kit 99 13 DOC ID 993223 PERFORMANCE Brock s Performance e 4064 E Patterson Road e Dayton OH 45430 e Phone 937 912 0054 e Fax 937 912 0062 Hayabusa Clutch Cushion Kit 99 01 Finally consistently smooth clutch operation from a Busa Introduction Congratulations on your purchase of the Brock s Performance Suzuki GSX1300R Hayabusa 99 01 Clutch Cushion Kit Part Number 270396 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 270435 is designed for use with these components and 270396 Caution must be taken to assure clutch spring coil bind Brock s HD and EHD clutch spring installed height of 790 inches minimum does not occur if any
5. Kit 99 13 DOC ID 993223 BROCK S PERFORMANCE PRODUCTS INC Hayabusa 99 01 Clutch Cushion Kit Installation Instructions 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 BrocksPerformance com 2 A complete listing of Brocks Performance policies and warranty information can be found at www BrocksPerformance com 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 Ib ft 95 Nm Warning If you are not skilled in replacing these parts PLEASE consult your Clutch Mod Instructions and Suzuki Manual Engine dam
6. age 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 the engine The remaining Steels will be
7. bly 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 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
8. 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 270461 and supplied Lever Cam Part Number 270422 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 at least 1 spring does not rattle FYI Even purchased new the Busa comes with several loose springs the
9. es 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 Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam
10. lace 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 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 BrocksPerformance com 2 A complete listing of Brocks Performance Products policies and warranty information www BrocksPerformance com 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 assem
11. 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 Lever Cam as described in the Lever Cam instr
12. 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 INSTALLED 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 the click 13 Set the Brock s Lever Cam to the desired position for you application as described in the introduction DOC ID 993223 Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam Kit 99 13 LEA Footie Wl 30H C eio Gmg u0n 91Ssu 0 0u23 soo s xxx 03141334S u028ui204202q ana 3siAu3u0 3300 LNG NOSGIAVG 300438 329NV33101 u29 MS Q DS 219 p G 9 obo uoo20 pa4isep ay oj jsn py ee Dq B PUDY BY SPJOMO J A 8u buyjnd Ayybys ajiym gf uoljisod oj uin uonisod jo jjo jsn po oj UONISOd 20 D S WOD 13427 30g 4 uo f uonisog 9joN NIIS ornoj ojsu DAOU8M UD 4949 ppjg 0 2y X paling iog pepoo7 buudg
13. uctions 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 DOC ID 993223 Installation Instructions Hayabusa Clutch Cushion Kit 99 01 amp Lever Cam Kit 99 13 03141234S 3SIA83H10 SS37Nn a 2088 Pn PON paal 230 13 020 uoiusn Fi OSNG 10 66 S000 3 C00 Buimoug Ajquassy muj SIO 0 03 X 03141334S 3SIA83410 SSIMNN 32NV3I3 ID uo2 8ui294 2040 MMA ONI S3ShHdH31N3 NOSGIAVG 32038 L99 18 p obog eunDbi4 3aS juauiS20jj buudg 10301 7 Z oN uly Had 9jOjd 49q j aunssaJg Ajquiassy pow YIINID 308 ajdung 0H 308 dm RUN u 9 043 308 NWN DUI Giang 1201S naasa 48usng u2 n 2 2 98 S u2jn 2 342015 JOYSOM 0G 10301 Z L ON 12101 9 0jd 48q j XIN3ANOI IV 3dOeld YOF dvjO dWf lgd WO xOJHO JDnuoW nzng seg 9 21 2 JOU U W 2D d xow 4214 Z u Z Jo ebog D JOJ pa4Oou84 DjSp LUOS 02S O JON M OPIS qui888y qoM paddns uoiusn abp S jong 1019 6 9 0Jg 89 S 1201s qn u2jni2 Jauu uoijsn 9Duo Jj 4039
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