Brockett - The later models had an updated carrier (clutch basket) put in and it solved the issue.
This is perhaps just for those with technical interest -
After comparing the old and new I found it was to correct an issue with the hardening, surface finish and accelerated wear caused by the loose inner spring plate that chatters about inside. Many owners have since proved it did not correct the rattle at idle and the 2,300 to 2,800 rpm vibration (chudder = shudder + chatter) that was there in all gears. The change they introduced made the problem plate that kicks off the vibration a little thinner and therefore weaker where it was seen to be breaking before. Vibration or chudder tends to crop up just as often in these with the revised inner plate fitted. Even 2012 bikes are getting the chudder with 5,000 miles on them over in the USA.
Before I explained how Suzuki also changed the needle roller bearing that the basket bears on. They deliberately spaced the rollers with a larger gap at one point so that it upset any resonance caused as the load shifted from roller to roller. The source of the resonance still being inside the basket and not the bearings evenly spaced rollers as they thought.
Brockett - Bad news for folk like me is the cost something stupid like £500+Fitting!!
The later clutch basket was fitted under warranty to many 02 and 03 bikes in the USA. About 1 in 20 I have re-engineered from the US are the earlier version. A new basket can be bought there for just under $300 USD. (£195.00). Oddly this comes close to our price if you import one once you paid VAT, packing and the shipping. I keep trying the online distributors over there but the final price you pay rises on their systems as soon as you enter UK as shipping destination. Its as if they are not allowed to sell at the discounts outside the USA (I use brand new for some owners who buy cheap and post over for the work to be done).
No such luck here in the UK where they were seldom attended to under warranty but its not all bad news. About 1 in 5 that came here from Europe are still the mark one basket. New in the UK is Just over £350 rather than £500. Equivalent in Euros in the rest of Europe. Bit less in Greece but the same once you paid the €40 plus to get them here.
Good news - well better perhaps. Most bikes existing baskets can be modified for no more than £245.00 including parts and post. The modification I do removes the concentrated loads from the problem areas. The load is shared as the original designers intended. Modified baskets have been stripped after many miles and show that they no longer deteriorate at the alarming rate of the Suzuki replacements.
Majority of owners remove and re-fit themselves which saves both time and money over the dealer. An easy job with slides that are out all over the place. Send them on to any who ask.
