Gt380 Clutch push pins.. How do they go back in?

[kayakboy]

I have a 75' GT380 and this is my first build(Newbie). When I got the bike upon inspection
I did notice the Clutch was not working. the Cluch cable actived push pin 1 was laying inside the
cover and pin 2 was stuck in thur the seal where is should be. Upon Putting the bike back together , I'm having trouble with pin 2, it only goes in about one inch.
Being a Newbie , and not familar with the shifting pattern of the trans, the back wheel turns with chin on, I assume the bike is in nutural. I have reservation about shifting the trans with out the clucth engaged.
So, do I have a problem ? or is there an easy fix? Thanks for the help!!

[yeadon_m]

Yes, if the chain turns without turning the motor over the bike must be in neutral assuming it's assembled correctly!
By push pins do you mean push rods? There are two, a short one hidden inside the hollow gearbox shaft that the clutch rides on, and alonger one in the same shaft, but sticking out the left side under the inner sprocket cover. The clutch cable actuator engages / pushes on that left rod.

Not sure I grasp the problem you have, so please post again!
Cheers, Mike

[kayakboy]

yes, I do mean push rods... I'm still confused. I understand that the two rods make contact to engage the clutch. Where does the longer rod go in?? When I took the bike apart the rod was in the round seal. I assumed thats where it goes back in, just above the small sprocket,or does it? Can you shed anymore light on my problem.... thanks MIKE!!

[yeadon_m]

Yes, the longer push rod goes exactly where you said. Then, the inner sprocket cover has the actuator operated by the clutch cable, and the end of that pushrod goes into the end of the actuator.
When the clutch lever is pulled, the mechanism pushes the pushrods through the clutch shaft and then lifts the clutch pressure plate, so to separate the clutch plates. Now the clutch can spin yet transfer no drive. It's easiest to see how it works if interested by taking the right side (clutch) cover off.
Cheers, Mike

[Barry S.]

Look up the parts here and you can see where they go. http://www.alpha-sports.com/suzuki_parts.htm" onclick="window.open(this.href);return false;

[kayakboy]

The diagram shows the long rod goes in half way thur the seal. when I originally removed the long rod it was in the correct position.
Now, reinstalling the rod it only goes in about 1 inch. In this position it will not match up with the actuator's small rod!!
Any other suggestions would be appreciated... Thanks!

[yeadon_m]

I am guessing that someone put another, long pushrod in there already. The one hidden inside is much shorter than the one in your hand. If you take the clutch cover and pressure plate off, you can prod it out and compare lengths. If I'm right then you need a new, short one, or cut down one of yours.
Cheers, Mike

[Barry S.]

http://www.oldjapanesebikes.com/mraxl_G ... index.html" onclick="window.open(this.href);return false; Look up the clutch and there are 3 pages that shows how to adjust.

[Coyote]

It sounds to me like something is out of line. Find a long rod the same diameter or slightly smaller. You should be able to push that ALL the way through. If you can't, something is obstructing the pathway. Also pay attention to the rod ends Starting from the left, one rod has a rounded end and the other end is convex. The second rod has a rounded end the rides in the convex end of the first rod. The other end of rod #2 is flat. That end goes against the clutch push piece.
Also note that these rods are soft with flame hardened tips. It is quite possible that one is bent. To be sure, roll them on a known flat surface like a pane of glass. They can bend if some PO didn't know how to adjust the clutch and over tightened everything. First pull on the lever bends the rod.

[kayakboy]

Well, I pulled off the Clutch pressure plate as suggested... low and behold, one long rod(7.5in) in length. I now have 3 rods. The shortest rod looks like it had been broken at one
time . When I removed the cover that houses the Actuator I found this rod laying inside.
So, the long rod I found inside should be replaced with the shorter of the two rods, Correct! If so.. everthing should line up and my problem is solved!!
Thank's folks for all your help!!!
Dave