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GS550 skipped chain - how bad is it?

  • Thread starter Thread starter kevinoneill
  • Start date Start date
sooo did the pushrod actually break off?
is it stuck in the hole?

I recall years ago my trusty mechanic waarned me that if the chain broke it would break or warp this rod requiring the cases to be split.

however i know that the rod can be pulled out and re inserted with no problems at all if intact and straight.

If there is enough rod left inside you may be able to force it through to the other sside through the hole in the centre of the clutch basket.

Did you cut it off and deburr it or did it snap off?
 
kevinoneill said:
ssure plate assembly, will not pull out, the gear hits the tranny case on the the way out.

I believe the other end of the clutch actuator attaches somewhere behind this assembly? it almost seems as though it goes right threw the center of it?? I don't know where to proceed from this point. Do I have to pull the motor out completely??
Click to expand...



The broken pushrod actually goes through the center of the hollow clutch shaft and pushes the clutch pressure plate away from the stack of clutch plates from the inside when you squeeze the lever. You can see the end of the shaft in the second picture, inside the hollow shaft. Use a suitable drift from the right side to push the pushrod back out to the left. May take a bit of tapping if it is very bent, the shaft it is inside of is steel and will take a little force without getting damaged. Might use the replacement pushrod as a drift to push the old one out, hopefully you won't have to hit it too hard and mushroom the end of the new one.

Also in the first photo, there was nothing attached to "A"... is that bad?

You have no kickstarter, but the place for one is still there from previous models. Suzuki went cheap.


IMG_3236.jpg
 
I got the rod out! :D

I just purchased one on e-bay, thanks for posting the link earlier. Here's what i bought...
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=150226677157

So with any luck, I'll have it by the end of the week, and next weekend, I can get it running again!

I did manage to snap it off (in half rather) on the left side, and then just pushed it threw, and it popped out on the right side with no effort at all really. Came right threw the center like you guys said.

I'm getting excited now :D
 
can we have a picture of the offending dead pushrod please?
 
I got into this part of my 250 many moons ago. There was a redesign from a single piece, oil leaking design to a two-piece oil-tight design.

Since it is a low-stress element, you might [have been] able to get away with straightening it. I'd first gently try straightening it in place before pulling it out. Once out, I'd use a reference surface (heavy plate glass, etc.) and get it as straight as possible.

About impact drivers:
  • Make SURE the driver bit exactly fits the screw
  • Hold it with a LOT of pressure in on the screw head
  • Pre-torque the driver in the direction you want to go (Don't forget the directional collar)
  • Replace those screws with SS sockets. Various ads on this site. I haven't, but it sounds like a good idea.
  • At least lube or anti-seize the threads when replacing the screws.
About drive chain: I'd look carefully into chain wear and sprocket wear. That shouldn't happen. If the sprocket is worn, the chain is too. Replace all three elements.

About diving into unknown mechanics. Bike Bandit and others have factory parts microfiche images on their sites. It can REALLY help with getting an overview of what you'll be getting into.
 
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I'll try and get a photo of the clutch actuator when I get home. The actuator is actually currently in 2 peices :( so straightening it won't be an option :p

thanks for the info.

I need to see about new seals. Not sure if i'm going to need some new ones or not...
 
Hmmm well i got the Push-rod... it is thinner than the one i took out...

eBay Auction said it was for 1980 GS550E, i have a 550T, i left them a note when i put my order in, to let me know if there was a difference between these models, would this part be good? didn't hear anything.

i put it in, and you kinda have to screw it a bit, when i turn it from the left side of the bike, i can hear parts rotating on the inside
 
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is there a special technique to putting the push rod in? with that screw on the end of it? you put it in i assume, and "twist it on" to whatever is inside the casing?

i put it on, but there is no pressure behind the clutch. i was able to get it to switch gears once or twice, but as i tightened down the clutch wire bolts, i lost all pressure and it won't change gears... :(
 
Maybe your new rod is too short, or maybe the screw gismo is not on the correct "thread"??
When it's in right the little cable arm should be about 90 degrees to the cable?
I think there is also a steel ball in there, to allow the clutch to spin and not spin the rod. Is that ball missing?
Look at a parts diagram, I haven't had one apart in quite a while.
 
Hmmm well i got the Push-rod... it is thinner than the one i took out...

eBay Auction said it was for 1980 GS550E, i have a 550T, i left them a note when i put my order in, to let me know if there was a difference between these models, would this part be good? didn't hear anything.

i put it in, and you kinda have to screw it a bit, when i turn it from the left side of the bike, i can hear parts rotating on the inside
 
i got it in ok, you have to screw it a bit to catch. only thing now is, the clutch doesn't release again once it's pushed in.. :( must be something wrong with the spring. i'll take another look later tonight
 
Talked to a few friends, i think the diameter might be causeing more of a problem than i think. So i might just call up Suzuki maybe and get the exact part from them... too busy to work on it lately.

oh and i WILL get this bike running again :p
 
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