Clutch Push Rod Problems

[Legionnaire]

My friend noticed that my clutch cable was fraying, so I ran to the store to get a new one made, and I tried to install it myself which was no big deal, but when I opened up the clutch cover to clean it out. I noticed this random rod was bent, turns out that is the push rod.

At the store the guy told me that a bent push rod would make it hard for the bike to dissengage/engage the clutch, is this true? I tried to bend it back and I must have made it worse, but now after installing the clutch cable I got on my bike and it wouldn't engage at all, I could just sit there in 1st gear and not go anywhere. I then adjusted my cable some more, but now my lever seems a little tight, but it is really hard to shift back down to 1st/neutral coming down to a red light. Sometimes it also creeps forward in first gear even with the clutch pulled all the way in, it also revvs between downshifts even where the clutch is all the way pulled in, it acts like the clutch isn't even engaged.

I am guessing that my problems lie in the bent push rod and a badly adjusted/routed clutch cable. If anyone could help me I would be extrememly grateful! Mainly what I am asking for is an explanation of the install of a push rod, I am guessing that the only bent part is the clutch side of the rod, not the other side, but do you think I should replace both while I am at it and how do I replace it, do I just yank it out and shove the new one in?

Thanks! (Sorry it's so long!)

[pete]

Firstly, remind me what you have... I recall it's a 450 but not the year

If you have the later two part pushrod, easy fix by just buying the short left hand side only, pull it out, and slot the new one in.

As for the clutch adjustment, I can't remember the best way to word it, but do a search on here and you will find Ed's (Nessism) method which is the most straight forward explanation ever.

[Legionnaire]

Firstly, remind me what you have... I recall it's a 450 but not the year

If you have the later two part pushrod, easy fix by just buying the short left hand side only, pull it out, and slot the new one in.

As for the clutch adjustment, I can't remember the best way to word it, but do a search on here and you will find Ed's (Nessism) method which is the most straight forward explanation ever.

I have a 1981 GS450! Pete... you are the best seriously! Thanks so much! I really just yank the pull rod out and push the new one in? If so... phew!

So I have a better explanation for what is going on... I was riding and it was completely fine and then after a while of riding it was really hard downshift in the lower gears, and everytime I would drop down a gear it would rev up like the clutch wasn't pulled in.

When I would sit in 1st the bike would creep and the idle would drop a lot, and there is NO way I could get in neutral with the bike on and idling it's almost impossible but the SECOND it turns off I can get in neutral. What do you think this is, just the problems I said earlier?

[pete]

I have a 1981 GS450! Pete... you are the best seriously! Thanks so much! I really just yank the pull rod out and push the new one in? If so... phew!

So I have a better explanation for what is going on... I was riding and it was completely fine and then after a while of riding it was really hard downshift in the lower gears, and everytime I would drop down a gear it would rev up like the clutch wasn't pulled in.

When I would sit in 1st the bike would creep and the idle would drop a lot, and there is NO way I could get in neutral with the bike on and idling it's almost impossible but the SECOND it turns off I can get in neutral. What do you think this is, just the problems I said earlier?

Mate don't count your chickens just yet... you may or may not have the two piece pushrod, I'm not sure exactly when they swapped them over.

If it's the two piece, the small one should pull out from the oil seal very easily and will only be a couple of inches long. If it doesn't, chances are you have the one piece which I believe means extracting from the right side after removing the clutch. At least the two pieces are still available cheaply from Suzuki so if it is the one piece you can replace it...

As for the dragging, I'd sort your rod out first, then make sure it's adjusted 100% correct and go from there.

[Legionnaire]

Mate don't count your chickens just yet... you may or may not have the two piece pushrod, I'm not sure exactly when they swapped them over.

If it's the two piece, the small one should pull out from the oil seal very easily and will only be a couple of inches long. If it doesn't, chances are you have the one piece which I believe means extracting from the right side after removing the clutch. At least the two pieces are still available cheaply from Suzuki so if it is the one piece you can replace it...

As for the dragging, I'd sort your rod out first, then make sure it's adjusted 100% correct and go from there.

Looks like it is a two piece push rod, I order the one piece a while back... luckily. So I just yank it out then? I am so excited to get my bike working right, thanks Pete!

[pete]

Looks like it is a two piece push rod, I order the one piece a while back... luckily. So I just yank it out then? I am so excited to get my bike working right, thanks Pete!

Yep just yank the small piece out from the left, just be careful you don't bust the oil seal. Let us know how you go!

[Legionnaire]

Yep just yank the small piece out from the left, just be careful you don't bust the oil seal. Let us know how you go!

I have had a hard time just yanking it out which makes me think it's a full rod... the OEM site I buy parts from says 2 piece, my Clymer manual says 2 piece, but the Haynes has an exploded view of "400 models" and I see a 1 piece rod... but when they say "400 models" do they mean 450s too?

I am gonna try to yank it again, but we will see what happens, it shouldn't be that hard should it?

[Mekanix]

Up to late 1981 it was all 1 piece.

The twin's which is all 400, 450, 500's have the exact same base, the only difference is the pistons, cylinders and heads.

The two piece is an upgrade and the manual show's that in the back of the book along with a few other upgrades that these engines got after 1982.


So, 1 piece or 2, they both work but the two piece is designed not to rip the oil seal apart because the 1 piece always rotates with the clutch and the 2 piece lets the small rod not rotate .

So pull the clutch cover off and the clutch pressure plate out and have a look down the center.

Try and reach over and turn or push the rod and see if its rotating on the clutch side. If so than its a 1 piece. If not then its just stuck.


You might have to straighten it out or cut it off if its the one piece because it wont fit through the opening even if its bent a bit and you have to drive it all the way out to the clutch side.


hope this helps,

[Legionnaire]

Thanks so much Mekanix for dropping all that knowledge on me! So if I open up the clutch side/right side of my bike to check/uninstall the push rod I need to take out the clutch or can I just do the twist test like you said and leave it in? Does that mean I need to get a new gasket for that side too when I open it up?

I am pretty sure it's a one piece because yeah it's bent, but there is no way it's gonna just get pulled out. Seriously thanks so much!

[Mekanix]

Yeah you might need that gasket or you might get lucky. all you have to do is take the cover off and then the clutch pressure plate. you Dont have to take the clutch out at all. Its really easy to do. But try and straighten the rod as much as you can. It might just come out with a little persuasion and bending as you go. The one piece can only come out the clutch side. You can replace the seal on the other side If it gets damaged as well.

[pete]

Cheers Mekanix, I haven't had to deal with the one piece rod before... I guess Suzuki mechanics/technicians had a few issues with bent push rods to deal with during the 250/400/450 life cycle...

[Legionnaire]

Yeah you might need that gasket or you might get lucky. all you have to do is take the cover off and then the clutch pressure plate. you Dont have to take the clutch out at all. Its really easy to do. But try and straighten the rod as much as you can. It might just come out with a little persuasion and bending as you go. The one piece can only come out the clutch side. You can replace the seal on the other side If it gets damaged as well.

Okay awesome simple advice... thank you so much! I bought a new clutch side gasket cause after 30 years I can only assume that it needs a new one, and I bought both sides of the push rod seal, and I also bought a push rod oil seal and shifter seal because I have a little bit on an oil leak and I can only imagine it's one of those two!

So many things coming in the mail, I am so excited!

[Legionnaire]

Okay so I have an update!

I bought the new push rod, the two piece one to replace my one piece rod and I open up the pressure plate and all that jazz to take out the old one and put the long side in instead. So I do that all nice and easy, torque it back up.

Now I go to the short push rod side/left side, and I slide in the push rod and then try to put the cover back on and the rod goes into the cases hole thing that it pushes against, but it doesn't slide on all the way. I crank down all the screws and it fits flush, but the clutch is INSANELY tight, even with all the adjustments as loose as can be it is still so tight.

I put the bike in neutral and scoot around it is all good, I put the bike in gear, pull in the clutch and try to move it and it feels rough, so that would be the clutch not letting go totally, right?

I am just so confused with all these clutch problems and would love some help! I feel like the push rod is too long, but obviously that would be impossible. Thanks ahead of time for any input!

[cowboyup3371]

Did you readjust the clutch after buttoning it back up using the procedures in your service manual?

[Legionnaire]

Did you readjust the clutch after buttoning it back up using the procedures in your service manual?

Yeah, but the first thing that made me feel like something was wrong was that I can put all the nuts/adjustment bolts and the loosest setting and it's still SO tight