I needs me a new clutch.

[Cosimo_Zaretti]

Ok, so I've decided that I want some new friction plates in my clutch on my 500E.  The current clutch is best looked at as anti wheelie technology.  At worst it feels like an old Holden auto box on takeoff and eventually lets go on hills in 6th.   The clutch swap itself doesn't daunt me too much, I have a pretty good idea what's in there, I've found some diagrams, instalation is the reverse of removal, make sure everything's done up to the correct torque and we're good to go.  That's the plan anyways.

What does worry me a bit is I've heard talk of some aftermarket kits for motorcycles not always using all the bits from the OEM setup, like maybe a shim or spacer or is meant to be left out.  Not sure if this is the case on the GS500 or not.  I'll be using an EBC kit cos they're cheap and easy to source.  Does the EBC kit exactly bolt in like the OEM setup?  Also given that the bike is 16 years old and has had a hard life, there's a good chance it's not the original clutch.  How do I tell whether it's got a suzuki clutch or an aftermarket setup when I take it apart?

Thankyou for your patience.

[Big Rich]

I don't know anything about the 500 clutch, but make sure you get new clutch springs too. Soak the fiber discs in motorcycle oil for about a day before installing them.

I couldn't imagine an aftermarket kit being too much different than stock (parts, not performance)

[madjak30]

I haven't had to do mine yet, so this may not be realavent...but I would pick up a kit (springs, plates, etc. included) and not just the friction plates...both should come with directions and diagrams, but like you said...who knows what's in there after a couple of owners and possibly a couple of clutch jobs...this one may have been done incorrectly and caused it to wear abnormally...(chances are this is the first clutch job...GS500s tend to live hard lives with little attention to maintenance)...but you don't really know what you are getting into, there could be broken bits in there for all you know...the kit will come with all gaskets, springs, plates, o-rings...(I don't really know what parts will be in there, but a kit should include everything)

I'm talking more from automotive experience, but it should be similar...never hurts to have a service manual either...

Good luck...

Later.

[skirecs]

the hardest part will be cleaning all the old gasket off the cover and case

that took 90% of the time for me

getting the cover off and the clutch off is like a 10 minute job

[gsJack]

My 97 GS started getting clutch chatter around 60k miles or so and I let it go since it only happened occassionally mostly on steep uphill starts.  I put 80k miles on the 97 before I replaced it with my 02 and my son put another 8 k miles on it before he replaced the engine with a low milage used one.  He tore the original 97 engine down and the clutch plates had a lot of lining material left on them.  Problem was weak valve springs getting weaker with the miles.  Could probably have been fixed with some stiffer aftermarket springs.  My 02 with 85k miles on it is starting to chatter a bit on uphill starts now, I'm just gonna put a 15T front sprocket on it with the new chain this spring.  

[4strings]

Installing new clutch plates is a breeze on the GS.  I did it last season.  Just make sure you look at the torque settings, hard.  In/lbs are very different from ft/lbs as it turns out

[Cosimo_Zaretti]

Installing new clutch plates is a breeze on the GS.  I did it last season.  Just make sure you look at the torque settings, hard.  In/lbs are very different from ft/lbs as it turns out

You mean I probably shouldn't do them up with the rattle gun?

The plan is to get gaskets, friction plates and springs, although for some stupid reason there may be a wait on the springs, so I might have to make do with the ones I have and replace the springs next oil change when I have the parts.  I will be changing the oil at the same time rather than trying to lay the bike over.

[4strings]

It was surprising to me when I did it that very little oil came out when I pulled the right side cover.  If you just put it all the way over on the sidestand you won't need anywhere close to a full quart of oil to refill it when done.  FYI, I think I remember a bolt or two holding that cover on hiding under the Suzuki logo behind the disk in there but a Clymers will tell all  .

[Cosimo_Zaretti]

I went to see my mechanic to see if he could get a hold of the EBC clutch kit for me in a hurry.  He was pretty helpful about the whole thing, and suggested I fit Ferredo friction plates instead.  After he'd made a few phone calls and arranged for the plates to be express couriered over I felt I should probably just pay him to fit them.  There's only an hour's labour in the job. 

[madjak30]

I went to see my mechanic to see if he could get a hold of the EBC clutch kit for me in a hurry.  He was pretty helpful about the whole thing, and suggested I fit Ferredo friction plates instead.  After he'd made a few phone calls and arranged for the plates to be express couriered over I felt I should probably just pay him to fit them.  There's only an hour's labour in the job. 

Sounds like he is a pretty decent guy...it's always a good practice to support the local guy (or is it a dealer?...I assumed here, since you talked directly to the mechanic)...they can be a real help when you are in a pinch...

Later.