2000 Hayabusa Clutch Assembly

Jord9999

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I have a 2000 Suzuki Hayabusa that needs a clutch. I have been confronted with two different assemblies. One assembly shows two steel springs at the back of the clutch pack and the other assembly shows the same part numbers without those springs. Can anyone point me in the right direction? The number I am referencing is 14 and 15 in the photo. Thank you!

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Kiwi Rider

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Welcome… question: where did you get these two different clutch diagrams from?
I’ve checked the Megazip listing for your 2000 model and all 3 regions worldwide show the same parts diagram… WITHOUT those two big spring washers.


If in doubt, remove your bike’s clutch pack and look to see if it has the two springs. If not, it doesn’t need them, if so just buy the plates and install them.

Jord9999

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Welcome… question: where did you get these two different clutch diagrams from?
I’ve checked the Megazip listing for your 2000 model and all 3 regions worldwide show the same parts diagram… WITHOUT those two big spring washers.


If in doubt, remove your bike’s clutch pack and look to see if it has the two springs. If not, it doesn’t need them, if so just buy the plates and install them.
I got the diagrams off of Revzillas OEM part section. I did take the clutch apart and there are multiple missing frictions and steels. I was not sure if I was missing anything else. Thank you!

Kiwi Rider

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I got the diagrams off of Revzillas OEM part section. I did take the clutch apart and there are multiple missing frictions and steels. I was not sure if I was missing anything else. Thank you!
You’re welcome.
Wow.. so somebody has assembled and installed the clutch pack with plates missing???
Why oh why do people mess with things when they clearly don’t understand how these things work. . .
Anyway, you’re getting it sorted so that’s great.
Let us know how it works out!

Jord9999

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I replaced the clutch pack and it was still not sitting flush completely with the pack and the plates were loose. Turns out a stuck slave cylinder as well.

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Jord9999

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I rebuilt the slave cylinder and it moved freely when using the clutch, but after I have pumped the clutch a couple of times I can not push the slave cylinder back in. Even with a c clamp the slave does not push back in. Does that mean the master needs to be rebuilt because a port is blocked?

Kiwi Rider

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I rebuilt the slave cylinder and it moved freely when using the clutch, but after I have pumped the clutch a couple of times I can not push the slave cylinder back in. Even with a c clamp the slave does not push back in. Does that mean the master needs to be rebuilt because a port is blocked?
Are you sure you haven't overfilled the reservoir?
Is the hose a rubber OEM hose?
Could be damaged and not allowing fluid to return?
Exactly what did you do to 'rebuild' the slave cyl? New parts?
Is the Slave cyl bore clean and free of corrosion/ridges?

Jord9999

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Are you sure you haven't overfilled the reservoir?
Is the hose a rubber OEM hose?
Could be damaged and not allowing fluid to return?
Exactly what did you do to 'rebuild' the slave cyl? New parts?
Is the Slave cyl bore clean and free of corrosion/ridges?
It is an oem hose and yes the slave was completely rebuilt. I found that if I take off the clutch level from the master the fluid can return if I push the slave.. If I put it back on i can’t push the slave back in.

Kiwi Rider

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It is an oem hose and yes the slave was completely rebuilt. I found that if I take off the clutch level from the master the fluid can return if I push the slave.. If I put it back on i can’t push the slave back in.
Do you mean 'clutch reservoir cap'?
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If so, I think the fluid level in the m/cyl reservoir is too high, reduce the level, fit the cap and try again....

Jord9999

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You’re welcome.
Wow.. so somebody has assembled and installed the clutch pack with plates missing???
Why oh why do people mess with things when they clearly don’t understand how these things work. . .
Anyway, you’re getting it sorted so that’s great.
Let us know how it works out!
Do you mean 'clutch reservoir cap'?
View attachment 1687977
If so, I think the fluid level in the m/cyl reservoir is too high, reduce the level, fit the cap and try again....
No if I remove the clutch lever I am then able to depress the slave piston in. I think someone may have installed or rebuilt the master cylinder with a faulty rebuild kit? Is that possible?

Jord9999

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If anyone is curious. I contacted the owner and he had installed a full rebuild kit from brake crafters made for this bike. The brake crafters stack up was 2.3mm longer than the OE set which he still had. Just thought I would update and say I swapped back to to the oe setup and everything works as it should with new oem parts. Below is a picture difference between the two. Thank you all for the help!

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