Clutch Issues

[Kijona]

Yeah I know, just yanking your chain 

Lol okay. Well consider my chain yanked.   

[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.

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.

Thanks, I used the magnets that pick up bolts and stuff when you drop them into engine compartments of cars. I'm really not trying to buy something that I can't use later so I'll just go with the manual for now.

[ragecage23]

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

Thanks for the video, but the part that I need is on the left side.

[ragecage23]

I'm going to make a short little video real quick just to clarify what I'm talking about.

[ragecage23]

Here it is. http://www.youtube.com/watch?v=_GIECYTcA2c

[Kijona]

Here it is. http://www.youtube.com/watch?v=_GIECYTcA2c

Hell dude...it's RIGHT there! All you need is a reverse drill bit or something...or maybe clean it up real good and see if you can use some heavy duty epoxy and glue something onto the end of it. I know this has been mentioned before but I was under the impression it was broken off somewhere between one side of the motor and the other.

Also, if none of the above works...you'll have to remove the RIGHT side of the crank case as others have mentioned, remove the clutch components, and push it out from the other side.

[adidasguy]

That seal is tight. Oil on the other side.
A cylindrical Neodymium magnet might grab enough to pull it out.
It shouldn't be in that far, so something is broken.
I'd vote to drain the oil, take off the right side and inspect everything as you get that thing out. You gotta have something wrong in there unless that shaft broke off and what's inside is all that's left. Still, if it broke off, you should check the clutch parts. Those shouldn't snap off (or be in that far).

[Paulcet]

Really, the question is: how did it break? Did the chain climb over the sprocket?  Did the cover get installed incorrectly? There should be no radial forces on that pin, only axial.

[Kijona]

That seal is tight. Oil on the other side.
A cylindrical Neodymium magnet might grab enough to pull it out.
It shouldn't be in that far, so something is broken.
I'd vote to drain the oil, take off the right side and inspect everything as you get that thing out. You gotta have something wrong in there unless that shaft broke off and what's inside is all that's left. Still, if it broke off, you should check the clutch parts. Those shouldn't snap off (or be in that far).

Damn. You're right...I didn't even think about the oil seal... and yeah, he said that it broke off right there, it's not pushed in.

OP: Yeah I'm with Adidas, man... take the right cover off and make sure everything's okay.

[ragecage23]

So if I take off the right side I should be able to see the push rod and I could just push it back out? Also, what are bad things that I should be looking for while inspecting it?

To Paulcet: It may have been the chain. Before I just installed this new chain I was milking the other chains lifespan (It was super loose)

[Kijona]

So if I take off the right side I should be able to see the push rod and I could just push it back out? Also, what are bad things that I should be looking for while inspecting it?

To Paulcet: It may have been the chain. Before I just installed this new chain I was milking the other chains lifespan (It was super loose)

You'll have to get into the clutch to get at it. As far as inspection goes...look for broken bits of metal anywhere within the clutch area.

[Paulcet]

Ok, if it was the chain that broke the rod, you might be lucky. If it was me, and I knew it was the chain, and the rod I got the rod out and it was not bent, I would stop there. But that's just me and that's a lot of "ifs".

[Kijona]

Ok, if it was the chain that broke the rod, you might be lucky. If it was me, and I knew it was the chain, and the rod I got the rod out and it was not bent, I would stop there. But that's just me and that's a lot of "ifs".

My guess is the chain had too much slack in it and jumped off the counter sprocket and smacked the rod.

It could've also just been coincidence and it had a stress crack in it or something.

[ragecage23]

Do I have to replace the gasket or can I reuse it? The bike is an '09

[ragecage23]

So I have the case off right now and I don't see where the push rod goes to. Can anyone help? I'm not familiar with how any of this works.

As far as broken pieces everything seems fine.

[Kijona]

Sorry, afraid I can't be of much help on the location of the end of it as I've never taken mine apart.

However, I would strongly suggest that you replace that gasket. Also, be careful handling the gasket, new or old. My dealer's manual for my 98 (really a 97) has a big warning about asbestos in some of the gaskets, and the side cover gasket is one of them. I dunno if they changed that or not but...like I said, be careful!

[ragecage23]

Alright, I'll get one of those. I can't see where the push rod even pushes on anything.

[twinrat]

Take off the clutch pressure plate ,That is the round lump with 6 bolts in it ,undo bolts evenly and underneath you will find spacers and springs remove carefully and underneath that you will find the clutch release bearing .pull it off by hand and dont loose the thrust washer ,make sure you put the trust washer  back facing the way you took it off as the surface should be niceley polished from use .UNDERNEATH is the  pushrod pusher pull this out by hand and you will have access to end of pushrod ...TORQUE the pressure plate bolts up ,4 to 6 nm.

[ragecage23]

Take off the clutch pressure plate ,That is the round lump with 6 bolts in it ,undo bolts evenly and underneath you will find spacers and springs remove carefully and underneath that you will find the clutch release bearing .pull it off by hand and dont loose the thrust washer ,make sure you put the trust washer  back facing the way you took it off as the surface should be niceley polished from use .UNDERNEATH is the  pushrod pusher pull this out by hand and you will have access to end of pushrod ...TORQUE the pressure plate bolts up ,4 to 6 nm.

Thank you so much! You don't know how much I want to be back on two wheels again. One last question for you: what is nm?

[mister]

Take off the clutch pressure plate ,That is the round lump with 6 bolts in it ,undo bolts evenly and underneath you will find spacers and springs remove carefully and underneath that you will find the clutch release bearing .pull it off by hand and dont loose the thrust washer ,make sure you put the trust washer  back facing the way you took it off as the surface should be niceley polished from use .UNDERNEATH is the  pushrod pusher pull this out by hand and you will have access to end of pushrod ...TORQUE the pressure plate bolts up ,4 to 6 nm.

Thank you so much! You don't know how much I want to be back on two wheels again. One last question for you: what is nm?

Here ya go http://en.wikipedia.org/wiki/Newton_metre

Michael