Successful Clutch Replacement (with questions)

[BoxTops]

It's good to be posting again.  I've been lurking, but had forgotten my password.   

So, here's the story.

After trying unsuccessfully a couple of times (http://gstwins.com/gsboard/index.php?topic=42845.0), I finally killed my clutch doing parking lot maneuvers.  Too much slipping, I guess. It glazed over, failed completely, removed all connection between my engine and the rear wheel.  I was at a steep lean when I lost power, and it unceremoniously dropped me on the pavement at the local DMV.  I thank God for armored jacket, gloves, and boots (all the gear, all the time), because I hit pretty hard.  I'm also thankful for the engine case guards that I bought for $40 or so a while back.  The right side case guard got a good scuffing, but nothing touched the case or covers.

I bought a spare engine for $100 from the fellow who sold me the bike, and last night I pulled the clutch plates from it and put them in mine.  I cleaned up the grit from the old clutch, refilled with oil, adjusted the clutch actuator (http://gstwins.com/gsboard/index.php?topic=21100.0) and cable, and took her for a test ride.  Readjusted the clutch cable, and all was well.

It's the deepest I have gone in the engine/trans, so I feel fairly accomplished.  Clutches are no longer a mystery to me.

Here's a question or two before I put her back on the road:

• What is the purpose of the plug (like a horizontal oil drain plug) on the right side case cover?  I don't find any posts on the topic.
• Should I do the oil flush procedure, since I found some grit from the old clutch in the clutch basket?  Anything to clean out that I haven't thought about?
• Where do you guys buy your gaskets?

Thanks for being such a great resource!

Ben

[GeeP]

Good to hear you changed your clutch without significant hangups.

Good for you, practicing parking lot maneuvers!  EVERYONE should practice in the parking lot on a regular basis.  The mark of a good rider isn't blasting down the road at 160, but handling his bike competently at walking speed.

To answer your questions:

1)  I believe the plug on the right side engine case is the oil pressure test port.

2)  If you found a lot of junk, I would try to get as much of it out of the cases as possible.  Run it for a few hours, then change the oil and see what comes out. 

3)  I get most of my parts from the local Mom and Pop Suzuki dealer.  They have a showroom about the size of my living room and a shop not much bigger.  However, they believe in old-fashioned service, so I do my best to support them.  I order a lot of aftermarket stuff from them too, through catalogs.  The price is the same, but they get a cut.

Good to see you around again, Ben. 

Have fun!   

[ivany]

A little OT, but you killed your clutch in a parking lot practicing maneuvers? Are these things really that fragile? I remember learning wheelies on my GS500, I must have been practicing in a lot for about an hour. That was a year and 6,000 miles ago...things are still solid.

[sledge]

A little OT, but you killed your clutch in a parking lot practicing maneuvers? Are these things really that fragile? I remember learning wheelies on my GS500, I must have been practicing in a lot for about an hour. That was a year and 6,000 miles ago...things are still solid.

The bike is 18 years old and we dont know how much abuse its had from its previous owners.

[BoxTops]

Post-action report:

As mentioned above, I changed the clutch plates.  I decided that I would possibly shorten the life of the engine if I didn't do all I could to get all foreign matter from the oil system.

I pulled the oil pan and it had lots of grit from the blown clutch.  Cleaned it out, waited a few days for the new oil pan gasket to arrive.

While waiting, I did the front brake pad replacement, replaced the fork springs with Racetech .85 springs, replaced the exhaust with a take-off I bought from a parts bike, filled the handlebars with lead shot to reduce vibration.  Gasket came in, so I put it all together, with new filter and oil.

It's like a new bike!  More back-pressure from the exhaust (old pipes had an automotive cherry bomb muffler welded on) seems to have helped throttle response, and improves acceleration.  I've never seen 10K on the tach before now, but it revs there easily now.  Front end doesn't dive during braking or bottom out when hitting bumps.  Brakes are what they should have been all along.

This bike is fun!

Thanks again, all, for the advice.

Ben