Suzuki 2 Strokes

I just reassembled the clutch on my GT-550. I don't have any oil in the case yet, but when i push down on the kick starter, it just slips and doesn't turn the motor. I took the clutch cover off and observed it....the kick start mechanism is working properly, but it just doesn't "grab" to turn over the motor.

Did I assemble the clutch wrong, or will the friction develop when I have the case full of oil?

Thanks,

Joe

My guess would have been a clutch re-assembly problem.

I guess I could have done something wrong with those "rubber rings" that go in there...or maybe I flipped one of the clutch discs around from where it was before. I'm really frustrated by this thing right now.

Is your clutch fully closed? Excuse me if I get this wrong, as I am a 500 twin man, but they all work pretty much the same. Check the clutch is fully closed. IE, free play in the cable, and a little slack in the worm drive adjustment.

Titan,

Thank you SOOO much.

I don't know how it happened but the clutch was indeed in need of adjustment. A few turns of that handlebar adjuster, and it was as good as new.

So, now I've solved the starter problem...no spinning with this clutch, as well as the sound from within the clutch.

Now, if I could only figure out why its blowing fuses.

After a few miles of riding, the clutch is better, but still not good. If I'm in 4th gear and really lay onto the throttle, it will slip and rev up real high...not slip out of gear, but slipping nonetheless.

Are there any other adjustments and/or tricks to observe when re-installing the clutch plates?

It looks like I may need to get a new set of discs, but they're darned pricey.

I'm not familiar with the 550 triples but the clutch lever should have an adjuster on the end of the clutch pushrod. On triples it's a nut and locknut arrangement. On RD Yamahas it's a locknut on a screw that screws towards the pushrod.

That end must be adjusted first. If there's no freeplay at the pushrod end, the clutch will slip. Do that first and then the cable.

edit:
I checked the service manual and it looks like you remove the small cover on the left to get to the clutch adjustment screw and locknut. Basically you loosen the locknut, turn the screw in until it becomes stiff and then back it out 1/2 a turn and lock it. Then adjust the cable.

If I look at the left side of the bike where the clutch cable goes into the block, there is a nut adjuster, I guess.

It's not like my old GT-185 where there was this little plate you took off under the bike and there were marks to align.

After finally finding that section in the horribly arranged OEM GT550 service manual, I see that I have to take that side cover off the left side in order to adjust the clutch there as well.

Hopefully I can get this clutch sorted out so I can get it timed and really take it on some long rides to start burning off some of that oil.

Take that left cover off. Loosen the jam nut. Turn in the screw until resistance is felt. Back off 1/2 turn and re-tighten the jam nut. At the lever, turn the adjuster to provide about 1/8" free play.
I seriously doubt your clutch is worn out. My GS1000 has 26,500 miles on it and it's still on the original clutch. It's just an adjustment thing.

I don't think it's worn out either. What I DO worry about though is that I got the discs out of order when I put on the new starter clutch....I'm an idiot for not making sure everything stayed in order. I have the general order (disc, driven plate, etc) right, I know that.

I've not found anyone else on the board having a problem with out of order discs, so I'm hoping its just an adjustment thing.

Hello again. have you made your adjustments? How is the clutch performing now?

If it is still slipping badly, I would try a new set of springs....they're not too dear. And...be sure to use the recommended grade of oil !

I'm going to make the adjustments this afternoon.

I have 20w50 oil in it right now.....I don't know if there is a particular brand I should be using...it's Castrol now.

The odd thing is that it never slipped before....and the only change I made was possibly to the order of the discs, and the new starter clutch.

With the clutch basket empty, the first one in is a cork one. Then steel - then cork------ You can't make any of the plates face to wrong way as they are 100% symetrical.
The last plate is cork. If your last plate is steel, it would slip big time.

Well, after doing the adjustments, it runs great. Thanks again for all the help.

Glad to hear you got it