Clutch replacement?

[Rallyfan]

Hi everyone,

The time has finally come. I've adjusted, 3-point adjusted, followed the adjustment threads and pictorials, etc. Back in 2018 I could adjust my way to a clutch that didn't slip. I no longer can.

I therefore now finally am convinced I need to replace the clutch.

I have some kinda basic, semi-embarrassing questions:

1. I can't find a complete kit. I can buy EBC friction plates but they don't come with metal plates or springs. I can buy EBC or Barnett springs alone but not in a kit. Has anyone found a complete kit, with friction plates, metal plates, and springs from a reputable source? Doesn't EBC sell an all-in-one kit? Or Barnett?

2. The $30-$50 kits on eBay are junk, right?

3. Do you change the gasket even if it comes off in one piece?

Thanks!

[Ghetto Garage]

When it comes to clutch work on these GS's. Unless your steels are warped, or blued, you dont need to replace them. Even if they are blued, normally a little 100 grit will get them ready to go again. Same with the springs. If this is the first clutch replacement, check the spring height, if they are within spec. Reuse them. Most of the time, these are medium wear parts.
For the simple answer to your question... To my knowledge, EBC no longer sells a whole kit. You'd have to check, but I think Suzuki still sells steels.

Cheers,
Mike

[Rallyfan]

Thansk for the response!

OK I'll have a look at the existing steel plates and see what they look like. One concern though: Did you mean 1000 grit (one thousand) and not 100 grit? I have seen people lay a piece of sandpaper flat on a bench and drag the steel plate across it but I thought it was fine grit sandpaper, not coarse?

[herennow]

I scuff mine up on a concrete floor....

[Rallyfan]

I see.

Maybe my way of seeing this case is too uptight (to quote The Dude).

On a whim, I ordered some Versah steel plates (read real reason here: because they were cheap and available...) because I could not find EBC steelies. I got the EBC frictions and springs coming in.

I'll have a look and see how silly my old steel discs actually look. If they are decent-ish I will go for the sandpaper. And I'll have the new steel discs for comparison and/or a "plan B."

[Rallyfan]

Hi again,

So I installed EBC "regular" friction plates, Versah steel plates, and EBC springs.

I followed these two videos:

https://www.youtube.com/watch?reload=9&v=KUgg2UN3gC4

and

https://www.youtube.com/watch?v=TbqLBfKYIsg


PROBLEM: My clutch does not disengage. I either have a very loose or a very tight lever. Either way, I don't get disengagement.

I did a 3-point adjust and I think my plunger pin isn't moving enough somehow, but I don't know why.

I only replaced the discs, I didn't remove the base of the clutch or the cassette itself (I did just like the videos).

Anybody know what I did wrong? I'm about to open up the crankcase again.

Thanks!

[HPP8140]

Not sure...hope one of the knowledgeable folks will chip in. I have 92,000 mi on my 2002 GS500 and have not had to touch the clutch. GL!

[Rallyfan]

Thanks nonetheless.

I'm the third (or more) owner and my clutch was done at 43,000 miles.

I took it apart and put it back together again and now the lever feels better! I can see my plates moving too.

However, I heard a POP! and I think I've blown the fuse because my oil pressure light no longer works. The other lights work fine though?! Hm. It's going to be a long night.

Any pointers appreciated everyone, thanks!

[Bluesmudge]

It's not a fuse. The GS500 only has the one main fuse and when it blows nothing works. Are you sure you didn't just unplug the sensor? Or that the bulb didn't burn out?

[Rallyfan]

I'm not sure, no. In fact I may have hallucinated the entire ordeal. My bike just... started. It runs great and now it also shifts great. I like the EBC/Vesrah combo I stumbled upon. Nice feel and nice solid grip. I can now accelerate in top gear once again -- much safer. Thank you.