Not AService Bulletin.

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Slipping Clutch on Suzuki's TL1000R

1: You need six flat steel washers with an internal diameter of 13/32" and an outside diameter of 3/4". The thickness is about 1/16" for most washers in that range I found. I had to drill the center hole but the outside diameter of 3/4" seems to be that of most 5/8" washers.

2: Drain the oil! I'd advise not doing this modification until you've covered over 3000 miles and intend to move to fully synthetic oil, or just need to change it.

3: Remove right hand side fairing, remove the the eight clutch cover bolts and gently ease off the cover. The seal is an "O" ring type molded rubber affair which should not need replacing.

4: Referring to Figure 1, remove one spring retainer bolt (1), then its corresponding spring (2) and lastly the locator pin (3). Click on the thumbnails below to view the diagrams. If the cover you removed doesn't reveal something akin to figure 2, go to the bottom of the class, replace the cover and remove the one just in front of the right hand footpeg. ;0)
 

Fig. 1	Fig. 2

5: Now place one of the washers on to the shaft of the locator pin (3) and fit the pin, figure 3 shows where the washer should end up. Replace the spring (2) and then the retainer bolt (1)... Looks like refitting is the reverse removal eh? ;0) Don't over tighten the retaining bolt as the locator pin is alloy, I highly recommend threadlock! A small dab of superglue on the thread would work okay too, but remember, someone may want to remove the clutch one day so make it a SMALL dab!
 
 

Fig. 3

6: Go round each spring in turn, inserting the spring as shown in fig. 3.

7: Re-fit the clutch cover, remembering to tighten the bolts in a diagonal pattern, don't over tighten, the cover is only plastic. The good news is it's probably not that expensive though! ;0)

8: Remember to fill the bike with oil again. If you replace the oil filter, which you should if you change the oil type you're using, prime the new filter with oil first and wipe a thin smear of oil around the sealing rubber - see appendix A. I'm sure you won't miss the fact your fairing is lying on the floor either.

9: Go and ride your TLR and feel very pleased with yourself.

Although this is what I did to my bike, and it appears to have stopped the clutch slipping, I cannot make any guarantees that it will cure the clutch problem on your TL 1000R. You must be aware of warranty issues related to unauthorized modifications to your bike and I cannot be held liable for any injury or damage caused by implementing this modification. You follow these instructions entirely at your own risk!

If you don't prime your oil filter by half filling it with oil before you fit it, you leave the engine un-lubricated until the filter paper gets wet and the filter fills up. Although this is only a short period of time it's still not a good thing. The smear of oil is so you can remove the sodding oil filter next time without any special tools or having to shred the thing with a screwdriver. If you know all that, great, but you'd be surprised how many people don't!