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2000 Suzuki GSX-R600 Clutch - Motorcycle Superstorewww.motorcycle-superstore.com/873178/d/2000-suzuki-gsx-r600-clutchClutch 2000 Suzuki GSX-R600 ... 2000 Suzuki GSX-R600 Clutch. ... it was easy to install and it was the first clutch system i ever put on my 2007 GSXR 1000 ...
this has to be done with a torque gauge, you tighten the head bolts to a specific torque, then a bit more not sure of what then you use a gauge and turn the wrench quarter of a turn I think but this is just to let you know you need a torque gauge, not a wrench although you need one of them as well. JUST PHONE A DEALER MATE usually helpful.
Your shifter cam bolt has backed out, this is a common problem on earlier GSXR's. Happened twice on my 2000, both times during race weekends.
Stop riding the bike and shifting at all and do the following repair:
Remove clutch cover - you'll drain some oil so make sure you have a drip pan underneath
Remove the 5 the clutch housing plate bolts - careful as they have pretty stiff springs behind them providing torsion
Remove all the clutch plates - make sure you keep the same order and re-install the same way; matter of fact if you have never replaced your clutch plates, do it along with this repair.
Once the clutch case is basically empty, you will see at the lower left a small assembly that looks a bit like a tuning fork, at the end of the shifter shaft. There is also a cam there with rounded cogs. There is a 8mm or 10 mm hex head bolt that holds this cam, and I'm sure it has backed out and is causing the cam and shifter to not engage the gears properly.
Remove the cam bolt. Spray some compressed air or even a light spray of brake cleaner in the threaded area where the bolt you just removed is. Make sure the threads are clean and dry.
Place the cam bolt and assembly back in its position, and take some RED loctite to the shifter cam bolt threads. Make sure to torque the bolt to specifications, I think it's 24 or 28 nm.
Let the bolt set for 24-8 hours, then reassemble the clutch and replace the clutch cover gasket. Top off the oil and go riding.
Chances are the prior owner installed some aftermarket springs that are too strong. This puts extra pressure on the push rod. Just pull the left and right cover of then remove the clutch assembly. put the new rod in from the left side then re-mount the left cover. Put the clutch back on then the right cover. The parts book shows a two piece push rod assembly. I wonder if a hardware store rod was installed because the factory rods are near impossible to find. The substitute rod probably couldn't handle the pressure and heat.
If not found elsewhere, google motorcycle salvage suzuki and see if you can find a used rod set.