2 pc. Clutch Push Rod Installation Help

[philo]

Hi,

I purchased a 2 pc. clutch push rod for my '81 GS250 as a replacement for the original one piece (the 2 pc. is a Suzuki OEM replacement from a GS450 that shared the same original clutch push rod as my 250). However, when I try to slide it into place (from the clutch side) it catches about half-way through. Has anyone installed the 2 piece clutch push rod that can give me some information about their experiences. Specifically did they have the same issue of it catching and how did they install it. Thank you for the help.

[Nessism]

I think half installs from the clutch side and the other half from the sprocket side.

[philo]

Yeah, I thought that would be the case with the larger piece installing from the clutch side and the thinner shorter piece from the chain side because the original push rod is thinner on the chain side and too narrow for the larger piece to fit through. But the larger piece stops about half-way through (it sticks out about three inches) on the larger opening on the clutch side. I looked through the shaft and it narrows slightly and that is where it is getting stuck. The larger piece has a cap on each end that is slightly larger than the rod itself and that is what is catching; the rod itself is the same size as the original. I thought maybe one of the caps would be removable but if it is it certainly is not easy to remove (by hand). If necessary I was thinking about using some fine sand paper and sanding the cap until it is the same size as the rod, or at least small enough to fit through, but I was not sure. Or maybe pushing harder, but I hate to brute force anything through, especially without posting on the forum. Any ideas or information would be really appreciated. Thanks for all the help.

[philo]

Here is a photo of the push rods, if that helps at all.

[pete]

I just replied on your other thread but I have a sinking feeling your bike is an '82 model which uses a completely different push rod going by the parts fiche...