BROCK DAVIDSON ENTERPRISES, INC.
www.brockracing.com
The
Brock
“So simple…you may have trouble figuring out how it works!”
Congratulations on your purchase of the Brock Davidson Enterprises (BDE) Suzuki GSXR Streetbike
Shootout Clutch Cushion Kit (Part Number: S11-CCK). The purpose of this kit is to remove the chatter
associated with running a lock-up clutch without wheelie bars. The BDE Clutch Cushion Kit will fun ction
with any lock-up on the market. We recommend the MTC lock-up (Part n umber: SFLG100 with the MTC
hardened buttons installed in the pressure plate) due to its design and tune ability.
The BDE Clutch Cushion Kit is not designed to compensate fo r failing clutch components. Inspect your
clutch hub, outer basked 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 Katana Part Number 21410-48B00).
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, the part numbers will vary depending upon which type of
crankshaft you are using (GSXR late model, early model, Katana, etc…) Also, inspect the outer basket
backing plate springs for sag. Shake the basket. If at least 1 spring doesn’t rattle, the baskets are usually
fine for a while, assuming the notches can be filed smooth. If all the springs are loose in the pockets,
rebuild or replace the basket.
The BDE Clutch Cushion Kit was designed to perform best with a STOCK hydraulic clutch system (not
cable) and GENUINE Suzuki steel and friction plates. Frictions and steels are available as a complete kit –
Suzuki GSXR (1990-1992) part number 21400-40C00. Aftermarket clutches ar e not reco mmended. If you
plan to sue your existing clutch, you will prob ably have an extra friction plate left o ver. Keep this plate for
use at a later time. We rarely install a complete new clutch assembly at once. Instead, the clutch is
regularly (every 4-5 passes) inspected for wear and/or damage. If any friction plates show signs of glazing
or smearing of the pads, or they measure less than the service limit (2.54 M or .100 inches) replace only
those plates. The same is true of the surface plate with the feeler gage. At the rack, 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 plates to turn blue and show hot spots. Don’t be alarmed. A no-bar rider MUST slip
the clutch off of the line to prevent wheelies or tire spin; this is what gen erates the discoloration. The
weight on the lock-up takes 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, naturally aspirated and artificially induced
horsepower, in addition to rider style affect every application differently. We have found that these BDE
Shootout specifications work the best as a starting point in a majority of situations. These are the EXACT
specifications used during out historic Seven second passes at Rockingham.
If you can’t run in the Seven’s with this set-up…the problem is not in your clutch!
Davidson Clutch Cushion Kit
Introduction
Page 1 of 2
BROCK DAVIDSON ENTERPRISES, INC.
www.brockracing.com
Installation
1. Read the Introduction on page 1 and study the enclosed assembly drawing on page 3. If you do not
understand these, please seek assistance from somebody who does.
2. Understand that the MTC lock-up clutch is NOT included with the BDE Clutch Cushion Kit.
3. There are no special tools required to install the BDE Clutch Cushion Kit. Standard tools to
remove/install stock clutches are required.
4. Begin by performing the inspections outlined on page 1.
5. If all components are in acceptable condition, reassemble the outer basket and clutch hub. Tighten the
clutch hub nut to the appropriate torque specification (101.5-115.5 lb-ft.)
WARNING
pump or alternator is not aligned properly, then SERIOUS and/or expensive damage may result.
6. Position the small lip of the cushion ring over the rear flange of the clutch hub. See lip/flange placement
note on the assembly drawing (page 3.)
7. Install the washer base over the clutch hub into the center hold of the cushion ring.
8. Position the washer, convex point facing AWAY from the engines, over the clutch hub into the center
hold of the cushion ring.
9. Position a STEEL plate, with the rounded edge (see note on 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
steel plates are a punched piece. The rounded edge is small – feel for it with your fingers. FYI: Ther e are
a total of 10 steels and 10 fibers used.
10. Install a FIBER plate, then another STEEL – this time with the rounded edge facing toward the engine.
The remainder of the steels will be positioned in this configuration. Continue the installation (steel – fiber
– steel – fiber – etc…) until you finish with a FIBER.
11. Install the clutch pusher 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 toward the engine with your thumb and forefinger. The pressure plate should now align an d seat
correctly.
12. Position the supplied springs in the pockets and install the MTC lock-up assembly. Be sure that the
lock-up levers do not bind on the pressure plate as you tighten the 4 screws in a diagonal pattern. There is
no need to add any MTC adjustment shims on the lock-up.
13. Add approximately 8.8 grams total of nut, bolt, and washer to ALL 4 levers on the lock-up. See
assembly drawing on page 3. These are standard steel parts supplied with the MTC lock-up kit.
14. Check the clutch for proper operation by visually inspecting the pressure plate movement as you
manually cycle the clutch lever. Be sure that the pressure plate does not contact the lock-up at full
disengagement of the bind at any point in the travel. NOTE: The clutch lever pressure of this system is
VERY strong. This is how it must be for proper “rider controlled” no-bar operation.
15. Replace the clutch cover (6.5-9.5 lb-ft.) Page 2 of 2
: If you are not skilled in replacing these parts, consult your Suzuki manual. IF the oil
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