• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Replacing the Pinion Release - GS650G 1982

Mr.humbucker

Mr.humbucker

Forum Mentor
Past Site Supporter
Need help ... I am in the middle of restoring an 82 GS650G and I've found a NOS clutch cover which looks real nice compared to the old one that was quite beat up. I figured that buying/using this NOS cover would save me from polishing the H out of the old one to make it look presentable. It is never that easy ... is it? What I didn't realize is that the NOS clutch cover didn't come with the pinion release (shaft), bearing or seal. I am hoping to recycle the pinion release from the old case cover and order a new bearing and seal.

My question/problem is .... how do you remove the pinion release? I suspect it is by heating it up (maybe) and using a puller of some sort? I have looked at the factory service manual but it does not seem to cover this in anyway.

Part 25 on this link - https://www.partzilla.com/catalog/suzuki/motorcycle/1982/gs650g/clutch
 
Looking at my spare cover, probably could do it with a large C-clamp...would need a appropriate sized pipe nipple or socket to straddle the bearing so shaft could push out of housing as C-clamp is tightened.
 
It's been a while since I worked on one but I think you can tap the shaft upward from the bottom. Oh, and while the cover is open would be a good time to replace the springs with new OEM parts.
 
Springs are easy: remove one at a time and replace with new. Regarding the pinion seal and bearing, replace both at the same time. Use a long rod and drive the pinion and bearing/seal out together, driving up from the bottom through a hole in the pinion tunnel in the cover.

clutch cover.jpg
 
Last edited:
Charlie G said:
I missed that you found this thread. Let me know if I can help (PM)
Click to expand...

Hi Charlie - you're a lifesaver posting that thread. VERY helpful. I found some time this afternoon, when to my shop (actually a garage but I like to think of it as a shop) and set out to follow your thread on how to remove the pinion. Fortunately I had a long handled file similar to the one you use with a tapered tip/end. I bent it up slightly, as you'd done and then devised a crudely made jig out of some 2x4 ends using 3" wood screws and secured the cover to my bench so it wouldn't flop around when I proceeded to hammer the end of the file.

Four strikes on the file with a hammer and out it popped. In all it took me about ten minutes to devise my securing jig, bend the file and pound it out. I am very pleased! I will now order a new bearing and seal.

I've taken Charlie's photo from his post to illustrate how it was done - Charlie if there are any royaltie$ from u$ing your photo I'll be $ure to send them along!

IMG_0348.jpg

I am not sure the effort is worth it for mostly cosmetic purposes but I like the challenge. I'll also order the springs and replace them as per the advice I've received on this thread.
 
Last edited:
You must log in or register to reply here.
Back
Top