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Clutch seems to hard to pull 1985 gs450l

  • Thread starter Thread starter dan0688
  • Start date Start date
pushrod does not apear to be bent. but does not look like the rod in my manual (see image) im assuming its a 2 piece pushrod and im only able to remove one portion without taking the otherside of the case apart? to check for the rod being bent the manual simply says roll it on a smooth surface. which i did and it apears to be striaght
 
Ranger said:
Can you take a picture of it? I can think of 5 different things you may be reffering to but its harder to give an answer without one.

I'm 99% sure I know what you're talking about but I don't want to give you the wrong answer. If its the little metal piece the end of the cable clips to that rotates and moves in or out with a small mech. on bearing then I haven't seen one broke but it is metal.
Click to expand...


ill go take a picture right now
 
One assumes you have installed it and oriented it correctly with the adjusting nut facing the outside left of the machine.
The locknut secures the threaded piece that is used to adjust the degree of clutch throw.


Where are the paralell twin guys tonight?
 
Ranger said:
I know the part but if you can take a picture of exactly what is broken on it that'd be good since its multiple pieces that make up just a #
Click to expand...

the inner screw like piece that is plastic was missing when i recieved the bike i was told it broke, im unaware of anymore having to do with it as i did not recieve the old part or any further knoledge of it
 
I also attached an image of the new one currently installed on my cover see previous post.
 
dan0688 said:
I also attached an image of the new one currently installed on my cover see previous post.
Click to expand...


Well it looks to be corectly oriented. when you place the cover onto the bike are you assuring that the pushrod makes its way into the hole in the center of part 24? If it sint then it would bind.

I would open up free play at the clutch lever and at the pushrod adjustment screw as well as the point where the clutch cable attaces to the cprosket cover.

That would let you slip the spriocket cover in place with no resistance.
From that point I owould follow the clutch adjustment procedure again to see what the result is.

I wonder if its the plates and fibres stuck fast or binding.
I would open it up to see. little to lose but a gasket.
 
dan0688 said:
I also attached an image of the new one currently installed on my cover see previous post.
Click to expand...


You could when you have it pulled off so theres no pressure on it, remove the cable from it real quick and check it with your hand to test the motion of it and feel for any binding. It should be smooth as hell.
 
I checked the cable with it off... it feels slightly rough... im gonna order a new suzuki one tonight and i will install it as soon as i get it and let you all know
 
Check your lever too. The pivot eye wears and the lever slides and binds slightly. It doesn't seem like much but it WILL cause enough binding to increase the effort required to pull in and be problematic with clutch release.
 
should i be able to push the clutch rod in with the sprocket cover removed? when i try to push it i can put excessive force on it without the rod moving at all....
 
Last edited:
dan0688 said:
should i be able to push the clutch rod in with the sprocket cover removed? when i try to push it i can put excessive force on it without the rod moving at all....
Click to expand...


You would have to be as strong as the sum of all the springs.
SO I am saying no and if you can remind me to never upset you.
 
You should not mess with the pushrod except maybe to pull it out being careful not to lose any parts ( I think there is a ball down the hole )
Check it for straightness on a sheet of glass maybe.
If you apply force to it you may bend it as the design only applies the force straight down the length of the rod. Side to side or wobbly input may bend it.
 
Dan pop off the clutch cover and check the plats springs etc.
You can do it without ruing a gasket if you are careful.

And take pictures.
 
ill try to get the cover off this weekend... i dont think ill have time before then im going to measure the springs with a caliper or micrometer for proper length correct? what should i be looking for on the plates?
 
I installed a new cable and the clutch pull effort got slightly better, contemplating weather or not im gonna tear it down this week and check the springs.... maybe the pull effort is normal... this is my first suzuki with a cable clutch...
 
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