05 gs500f clutch issue

bryanfischer20 · July 25, 2014, 07:39:36 PM

Hello, I am finishing a complete overhaul on my gs500f. Here is what is happeng, I pull the lever and it just does engage the clutch. I have both covers off the side and am suspecting it is something with the pushrod. I adjust everything to there max and it just does not engage. I can can push #20 by hand and #13 moves but when I put everything back together it just doesnot work. Any ideas?

[attachment deleted by admin]

Suzuki Stevo · July 25, 2014, 07:50:12 PM

Rough Adjustment #25 in your photo (#6 in image below)?

bryanfischer20 · July 25, 2014, 08:07:40 PM

Thank you for the reply but I turn that screw all the way in and i do not feel any Resistance at all.

Suzuki Stevo · July 25, 2014, 08:23:23 PM

Quote from: bryanfischer20 on July 25, 2014, 08:07:40 PM
Thank you for the reply but I turn that screw all the way in and i do not feel any Resistance at all.

Either your pushrod is too short, or something is missing from the primary drive side??

Is ~~#13~~ & #14, #15 in place? Ok, you said #13 moves...

bryanfischer20 · July 25, 2014, 08:37:18 PM

yes they are, how long is the push rod apposed to be, may be mine broke or something? Pictures on how far it is appose to stick out? Thank you for you help.

Suzuki Stevo · July 25, 2014, 08:49:01 PM

Quote from: bryanfischer20 on July 25, 2014, 08:37:18 PM
yes they are, how long is the push rod apposed to be, may be mine broke or something? Pictures on how far it is appose to stick out? Thank you for you help.

The ends of the pushrod should be rounded and look the same IIRC, I have no way of coming up with a length.

bryanfischer20 · July 25, 2014, 09:14:37 PM

dam, the the ends look exactly the same

bryanfischer20 · July 27, 2014, 08:39:41 PM

ok, so after messing around i put around a 1in long broken bolt between 19 and 20 and it seems to work good. Any ideas

X-ray · July 27, 2014, 10:45:01 PM

Not to say you haven't, but be methodical in all your adjustments. Unless your push rod is obviously broken(which it doesn't seem) sometimes the simplest solution is the hardest to find.

89500inPA · July 28, 2014, 12:10:22 PM

A few years ago I did the same thing, rebuilt the clutch on my GS500. When I got it together, I had the same result, no clutch engagement and no response to the lever. I took it apart again with much cursing and swearing, and it turned out I had not allowed the clutch basket to engage correctly. A little twist to the side and the whole thing moved into it's correct place.

Got it back together and it ran better than ever.

News:

05 gs500f clutch issue