72 gt550 clutch problem?

[carson shmarson]

I got my engine all in and put clutch and everything together, there is oil in the case. I went to adjust the clutch and it isn't working. I pull the lever and the clutch isnt disengaging. I used the manual to adjust the clutch properly. (I even purposely over tightened it to see if it worked) Does the engine need to start to get the clutch lubed properly. I dipped each plate in oil upon assembly. Did I maybe over toughen the clutch spring bolts maybe. Oh and my softer isn't springing back by itself when I shift. I wasnt sure tho again if the engine needed to turn to lube anything or ? Any help or knowledge would be appreciated thanks. -Carson

[Alan H]

If it's together correctly, the clutch will disengage when the engine is in gear. Try putting it in first and pulling the clutch lever, then kick the engine over. I assume you mean shifter? That sounds like the springs in the shifter aren't in correctly. That's under the right casing at the back.

[carson shmarson]

Ya the auto correct got me, shifter I meant. I can drain the oil and check the shifter spring. And I haven't ever started the engine yet I still need to get the pipes installed. I put it in 1st to roll it forward pulled the clutch lever to roll it to check the clutch adjustment and it isn't disengaging. I was wondering if I needed to start the engine before the plates would spin and disengage the clutch. I wasn't sure I haven't ever rebuilt these bikes before. Thanks again I'll yank off the cover tho to check the spring. I did soak all the clutch/friction plates in oil before I put it all back together. It has been a couple months tho too.

[ConnerVT]

Auto correct could of done worse. "softer' is better than some alternative spellings.

[carson shmarson]

Thanks you were right when I installed the shifter rod the spring was in wrong it's perfect now. I just pulled everything apart last night and I can't figure out the clutch problem. If all the gears are lined up for the starter, crank, etc is the clutch (basket I think it's called) on right. I did have the whole thing apart then reinstalled it on the shaft. I was hoping if I pulled the clutch friction n pressure plates I'd see a problem I didn't tho. I'm stumped here still when I tighten the cable down the rods move but nothing with the aluminum clutch basket pieces. They don't move at all

[yeadon_m]

Its quite a simple system really - the lever/cable operate a rotating ball + ramp pusher under the left cover which pushes on the two pushrods and these push on the 'mushroom' in the centre of the clutch inner, which in turn pushes on the clutch top (the piece with 6 springs and bolts) to lift the top and thus release the plates.

So something isn't right. My guess is either a rod is missing or the wrong length, or the mushroom is missing.

What does the clutch lever 'feel like' as you pull on it? it should be a smooth resistance which is constant in level as soon as it begins to push on the release system described above.

Good luck,
Mike

[Alan H]

You have got the clutch push piece in there? Item 20.
Here's what it SHOULD be assembled like.

CLICK FOR MORE DETAILS

[carson shmarson]

i see how it should work the piece #21 above i dont see that one, i have the rods, cable end, mushroom piece (that mushroom piece moves just isnt pushing the cover out.) when it hits the cover its hard and not moving at all. the lever gets hard to pull and wont move when it presses against the cover. i tried with the bolts almost all the way out too so just in enough to hold the springs from falling out, as well as tightened to 5 ft lbs of torque. or does the cover not really move out at all just enough to release pressure on the friction/clutch plates. thanks for the help so far. i really appreciate it.

[yeadon_m]

#21 is an oil seal and you will probably find it stuck into the clutch cover recess, it isn't attached to the clutch.

[Alan H]

The clutch outer - item 13 - MUST move when you pull the clutch lever in, otherwise the plates don't release.
Take the clutch outer off and operate the clutch lever with your finger on the end of the rods, or if they are inside the clutch centre then put another rod or bolt in the centre so that there is something to touch. When the lever is operated the rods MUST move, otherwise either the cam drive (parts 22-26) isn't operating, or the clutch isn't mounted correctly on the centre shaft.
To adjust the clutch, slacken item 29 and tighten item 27 until it's bottomed, then turn back half a turn and nip up the nut. When you operate the clutch lever the cam turns, and rides up on the balls in item 23 making the rods push away to lift the outer clutch plate and relieving tension on the plates. If it doesn't, then it's incorrectly assembled or something missing.
Item 23 should have 3 balls which go into the detents in items 22 and 24 at rest, and out of the detents when the clutch lever is pulled.

[carson shmarson]

After many hours I think I found the culprit. This sprocket cover didn't come off this motor originally, it wasn't flush on the bottom, so I think it's not giving me enough movement when I pull the clutch lever. I have it loose now and or really doesn't want to go on flush. It may be off a newer bike. Mine is a 1972. Thanks so much for the help, I used your answers to find that my clutch was in fact together correctly. So thank you guys. I may have to file an edge or two off this sprocket cover., the guy who sold it to me claims it's off a non-wrecked bike that was in running order. (He made more parting it out than selling it) so maybe they varied in newer yrs I'm not sure. It appears all straight to, but it's not going on flush all the way around (the sprocket cover) was wondering if this happens or maybe this sprocket cover isn't fitting right for a reason like a difference in the 72 and later years

[Alan H]

All details on here - http://www.alpha-sports.com/suzuki_parts.htm" onclick="window.open(this.href);return false;

but the outer and inner covers are the same part numbers for all years, so there's something stopping it going on properly.
If you clean the faces that don't go together properly, then lightly paint one of the faces, where they touch will show.
You might find that you have to slightly ease the silencer to allow the cover to seat.

Only use a small hammer!!!

[carson shmarson]

Good idea with the paint, I'll try that when I get home. It's really tough to get on by hand so I can try light tapping too. Thanks again

[carson shmarson]

Oooo-kay that paint thing worked the sprocket cover must have been a different year than the engine case, it had a "line up lip/to hole" where the frnt lower bolt has a round lip that slides into the (a little bigger than the bolt hole)hole in the engine. I'll post pix. The problem was the engine had one of these line up lips also. So it wasn't going in flush because the lip was on the engine case and the sprocket cover and one or the other was supposed to have the indent for the lip to slide into but neither did. MAN THIS IS HARD TO EXPLAIN LOL. Soon here's some pix. Hopefully down the road this will help someone. So I drilled the lip thing and it lined up perfect, bolted right back together, the clutch works perfectly. Thank you for the help guys You guys are awesome.

[carson shmarson]

Got the pix finally