Replacing the Pinion Release - GS650G 1982

[Mr.humbucker]

Need help ... I am in the middle of restoring an 82 GS650G and I've found a NOS clutch cover which looks real nice compared to the old one that was quite beat up. I figured that buying/using this NOS cover would save me from polishing the H out of the old one to make it look presentable. It is never that easy ... is it? What I didn't realize is that the NOS clutch cover didn't come with the pinion release (shaft), bearing or seal. I am hoping to recycle the pinion release from the old case cover and order a new bearing and seal.

My question/problem is .... how do you remove the pinion release? I suspect it is by heating it up (maybe) and using a puller of some sort? I have looked at the factory service manual but it does not seem to cover this in anyway.

Part 25 on this link - https://www.partzilla.com/catalog/su.../gs650g/clutch

[tom203]

Looking at my spare cover, probably could do it with a large C-clamp...would need a appropriate sized pipe nipple or socket to straddle the bearing so shaft could push out of housing as C-clamp is tightened.

[Nessism]

It's been a while since I worked on one but I think you can tap the shaft upward from the bottom. Oh, and while the cover is open would be a good time to replace the springs with new OEM parts.

[Mr.humbucker]

Oh, and while the cover is open would be a good time to replace the springs with new OEM parts.

Is there much to replacing the springs? Are they a simple in/out? I can only hope!

And ... I found this thread after searching for a bit on the pinion ... likely won't be an easy go at least not for me. We rack it up to a good learning experience ... I hope.

http://www.thegsresources.com/_forum/showthread.php?157735-Oil-seal-clutch-shaft-650g&highlight=clutch+seal

[Nessism]

Springs are easy: remove one at a time and replace with new. Regarding the pinion seal and bearing, replace both at the same time. Use a long rod and drive the pinion and bearing/seal out together, driving up from the bottom through a hole in the pinion tunnel in the cover.

clutch cover.jpg

[Charlie G]

https://www.thegsresources.com/_forum/showthread.php?157735-Oil-seal-clutch-shaft-650g&highlight=

Take a look at this thread. I created it in 2010 and I outline how I changed the seal on my 650g. I hope the photobook pictures are visable to you. I still have the seal setting tool and would consider sending it to you. Hope this helps

cg

[Charlie G]

Is there much to replacing the springs? Are they a simple in/out? I can only hope!

And ... I found this thread after searching for a bit on the pinion ... likely won't be an easy go at least not for me. We rack it up to a good learning experience ... I hope.

http://www.thegsresources.com/_forum...ht=clutch+seal

I missed that you found this thread. Let me know if I can help (PM)

[Mr.humbucker]

I missed that you found this thread. Let me know if I can help (PM)

Hi Charlie - you're a lifesaver posting that thread. VERY helpful. I found some time this afternoon, when to my shop (actually a garage but I like to think of it as a shop) and set out to follow your thread on how to remove the pinion. Fortunately I had a long handled file similar to the one you use with a tapered tip/end. I bent it up slightly, as you'd done and then devised a crudely made jig out of some 2x4 ends using 3" wood screws and secured the cover to my bench so it wouldn't flop around when I proceeded to hammer the end of the file.

Four strikes on the file with a hammer and out it popped. In all it took me about ten minutes to devise my securing jig, bend the file and pound it out. I am very pleased! I will now order a new bearing and seal.

I've taken Charlie's photo from his post to illustrate how it was done - Charlie if there are any royaltie$ from u$ing your photo I'll be $ure to send them along!

IMG_0348.jpg

I am not sure the effort is worth it for mostly cosmetic purposes but I like the challenge. I'll also order the springs and replace them as per the advice I've received on this thread.