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850 Clutch Drag

49er

49er

Forum Sage
Past Site Supporter
Since I first bought this bike, it has suffered clutch drag to varying degrees.
The PO was running Shell Advance 20W50 synthetic which I used for the first 3 years. It had severe drag when the engine was cold.

Since rebuilding my engine, I have fitted Barnett Clutch Plates and HD springs. I run 10W40 or 5W40 and the drag has reduced considerably. My clutch drags when the engine is cold and I select 1st gear. Also when stopped at the first intersection. If I don't get into neutral before stopping, I can't get the bike out of 1st without turning the engine off. I can ride the front brake with some throttle on and avoid this problem, but it shouldn't be necessary to do this.
When the engine reaches normal running
temperature, it doesn't drag at all. It would be great to completely eliminate this drag all together.

The Clymer manuel states that early 79 model 850's experienced this problem up to GS850GN 109445. My engine # is in this range. The remedy was to fit an improved Release Rack P/N 23165-45101 to all later models and they recommend this change to the earlier models.

Has anyone fitted this later release rack to their 79 850's? Did the new rack completely remedy the drag problem?
From previous posts on this issue, some suggest that going back to new standard springs may eliminate the drag.
I would appreciate some feedback from members who have replaced this rack. What was the major difference between the old and new rack design?
Thanks
 
49er said:
The Clymer manuel states that early 79 model 850's experienced this problem up to GS850GN 109445. My engine # is in this range. The remedy was to fit an improved Release Rack P/N 23165-45101 to all later models and they recommend this change to the earlier models.

I would appreciate some feedback from members who have replaced this rack. What was the major difference between the old and new rack design?
Thanks
Click to expand...

Well, once again we have the same problem on our '79 850's. My engine # is XGS850-104976 but note--it is preceeded by an "X". Anybody know what that means?

I have a Technical Service bulletin Suzuki produced in 1979 which shows a diagram of the release rack. The only difference is that the hole at the rack end of the improved part is much smaller (1.2 mm) than the hole at the other end (5 mm). The original rack has a 5 mm hole at both ends. The effect of the change is that the oil supply to the clutch plates is reduced. I will be glad to scan the Bulletin and e-mail it to you in a day or so.

I was going to fit the new rack myself, but I ended up thinking I could live with the problem until I removed the cover for something else. Thinner oil and not filling over half-way up the sight glass helps minimize the problem.

Here's something I wondered about: I think the same oil supply that supplies the rack also oils the top end. Suzuki later (in '82, I think) fitted an oil jet in the clutch cover (between the rack and the oil supply) and I'm guessing it was to relieve oil pressure so that the top end would not be over-oiled. This is strictly speculation on my part. I don't know what the end result of over oiling the cams would be. I have never had the clutch cover off nor have I read any thing to this effect. But somewhere in the OEM Service Manual there in an oil flow chart and looking at it seemed to suggest this theory.

I bring this up simply for what it's worth. After looking at the chart, I see that oil supply also oils the Transmission and the Crankshaft Journals, too. And usually, most cams are under lubricated, right? So like I say, FWIW.

Hope this helps.

Tomcat
 
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I put up with that problem ever since I changed the clutch, (barnett) don't think it's quite as bad as yours but it is worse than stock, I cant seem to get enough travel at the arm on the clutch end of the cable to completely release the clutch. I've ordered a new clutch lever.
 
Thanks tomcatt and derwood.

Like you derwood, I think that the clutch release is minimal considering that there are eight plates and discs that need decent seperation to break the friction effect of the oil films. I was hoping that someone had visually checked the two racks and found that the new one was designed to increase the seperation through a higher gearing of the mating teeth on the rack.
Tomcat, I would appreciate a look at that service bulletin showing the release rack diagram.
Thanks
Ian
 
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