Clutch Issues

[ragecage23]

So I'm a little confused about what happened to my clutch. Here's the story: I was on my way to work on the freeway and I was going to shift from 5th to 6th, I heard a pop and I got stuck in between the gears so it was like I was in neutral. I finished off the shift without using the clutch. I got off the freeway and tried to downshift, but there was no pressure in the lever so I had thought that my cable broke.

Later during inspection my cable is fine and fully in tact with no fraying, when I squeeze the clutch lever there isn't any pressure, but it returns to the normal position just like any other clutch lever. So, does anyone know what might have happened?

[Suzuki Stevo]

If you would have thrown the chain I would have said "bent push rod". When you pull in the clutch does the case over the CSS bow out?<grasping@straws

[ragecage23]

I'm not exactly sure what the CSS case is, but I took the two screws off the left side case to open that small compartment and when I squeeze the clutch it twists counter clockwise and moves inward, towards the engine.

[Suzuki Stevo]

CSS=Counter Shaft Sprocket, I have seen a bike in the past where the cover over the CSS was only held on by 2 or 3 fasteners on one side, whenever the clutch was pulled in the cover bowed out. The little cover is for the rough clutch adjustment (see photo) Is your push rod intact?

[bombshelter13]

Take off the cover over the clutch mechanism and sprocket (it's the piece that the small oblong piece you unscrewed is in).
The piece you're looking at behind the small cover, when it turns it pushes a rod (hence, a 'pushrod'). What the previous poster's suggesting is that this pushrod could be bent. If it is, you should be able to tell by sliding it out (just pull it out) and looking at it.

[ragecage23]

Oh okay, I get it. I'll look when I get some time on my hands. Thanks again everyone.

[ragecage23]

So, turns out that the push rod has exploded into 4 pieces, 3 of which I have, but the 4th piece is lodged into the hole that the push rod goes into (on the engine side) and I can't get it out. What could I do to get it out?

[Dizzledan]

If you can find a magnet small enough, that'd be the key. <Good idea
Turn the bike sideways and bang on it < Bad idea
Put industrial glue on your old piece and try to fish it out <Bad idea
Otherwise you'll have to take the right side engine cover off and take off the clutch springs to get at it. <Best idea

[PolarBZ]

Would push rod explosion be caused by anything specific, or just something that everyone should expect to happen?

[ragecage23]

If you can find a magnet small enough, that'd be the key. <Good idea
Turn the bike sideways and bang on it < Bad idea
Put industrial glue on your old piece and try to fish it out <Bad idea
Otherwise you'll have to take the right side engine cover off and take off the clutch springs to get at it. <Best idea

I'm going to go with magnet and glue haha

[ragecage23]

Would push rod explosion be caused by anything specific, or just something that everyone should expect to happen?

I don't know, but when it happens, it sucks.

[ragecage23]

Is it number 19 or 20 that i need? I'm thinking it's 20.

[Dizzledan]

As long as you pulled out a whole pushrod from your sprocket side (#19), I'd think you'd need part #20 as well. Even if you do get all the bits out of the hole, I'd still take the clutch cover off to inspect things, and to make sure that none of the pieces are botching up the gears in there and otherwise causing havoc. Taking the cover off is pretty easy, but you do have to drain the oil and take your time.

[ragecage23]

As long as you pulled out a whole pushrod from your sprocket side (#19), I'd think you'd need part #20 as well. Even if you do get all the bits out of the hole, I'd still take the clutch cover off to inspect things, and to make sure that none of the pieces are botching up the gears in there and otherwise causing havoc. Taking the cover off is pretty easy, but you do have to drain the oil and take your time.

Oh okay, good point. I'm just not very mechanical savvy. I'll do what I can.

[ragecage23]

So magnet and glue didn't work. I'm going to attempt to take the engine cover off. This will be my first time doing anything major like this so can anyone give me any important tips? I don't even know where to start.

[Kijona]

So magnet and glue didn't work. I'm going to attempt to take the engine cover off. This will be my first time doing anything major like this so can anyone give me any important tips? I don't even know where to start.

Drain the oil first. Before you go taking that thing apart find yourself a shop manual. Most Suzuki dealerships should have one for you, if not, you can order one. They're about $30-40, depending. And let me tell you...they're worth EVERY penny. Clymer is pretty good from my experience.

But STOP! There's a better way to get the stubborn bugger out. It's a long shot but see if you can find a REALLY powerful magnet and put it on the end of the "good" piece of the rod and put it down in there. You might be able to get it to come out. Another option might be to see if you can get a metal coat hanger and use a magnet. Harbor Freight and Northern Tools both sell really big magnets for next to nothing.

[Kijona]

Something else you might try is a TINY amount of super glue on the tip of the good part. Make sure it's just a DROP or else you'll risk getting super glue in your motor. Not good! 

[Dizzledan]

So magnet and glue didn't work.

...find a REALLY powerful magnet and put it on the end of the "good" piece of the rod and put it down in there.

...a TINY amount of super glue on the tip of the good part.

How much of this thread did you read?


All kidding aside, Kijona is right about the manual. I have a haynes and its the number one tool that gets used when working on my bike.
If you want the manual and buy from this link:
http://www.amazon.com/exec/obidos/ASIN/0892878339/gstwincom
GSTwins get some money.

As for the engine case removal, I made  a clutch replacement video that show the case removal here:
http://www.youtube.com/watch?v=KUgg2UN3gC4

[Kijona]

So magnet and glue didn't work.

...find a REALLY powerful magnet and put it on the end of the "good" piece of the rod and put it down in there.

...a TINY amount of super glue on the tip of the good part.

How much of this thread did you read?


All kidding aside, Kijona is right about the manual. I have a haynes and its the number one tool that gets used when working on my bike.
If you want the manual and buy from this link:
http://www.amazon.com/exec/obidos/ASIN/0892878339/gstwincom
GSTwins get some money.

As for the engine case removal, I made  a clutch replacement video that show the case removal here:
http://www.youtube.com/watch?v=KUgg2UN3gC4

I read all of it I was suggesting a specific type of magnet AND glue. Maybe he didn't use a powerful enough magnet or some other type of glue! Just trying to help.

[Dizzledan]

Yeah I know, just yanking your chain