Question about 1990 Suzuki GS 500 E

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Bleeding a Suzuki GSX1100G Clutch

I am putting new friction plates on the bike. I can not get the push rod into its hub far enough to reassemble the clutch. I am hoping bleeding the clutch will help.

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6 Suggested Answers

6ya6ya
  • 2 Answers

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Posted on Jan 02, 2017

  • 2 Answers

SOURCE: Clutch bleed on a Suzuki 1400 Intruder 2000

One the left-hand side of the bike (facing forward), there is cover plate just ahead of the drive shaft. Remove that cover (mine has 8mm bolts). The bleeder valve is under this cover. Go to an auto parts store and get a "one man bleeder kit" or if you have some plastic tubing that will fit over the valve, you can use that and a clean jar. Follow the instructions on the bleeder kit, or if you're using the jar and tubing, fill the jar about a quarter of the way with break fluid (use DOT4, but never DOT5!). Take the cover off the master cylinder up at the handlebars, place the tube over the end of the bleed valve (after loosening it a turn or two. Place the other end of the tube down in the break fluid in the jar. Work the clutch lever until you stop getting bubbles in the jar. Be sure to keep the fluid level up in the reservoir. Tighten the bleeder valve, remove the tubing, top off the fluid and replace the covers.

Be careful not to get brake fluid on anything. It will eat paint and mess up other things.

Posted on Feb 13, 2009

tellme2
  • 137 Answers

SOURCE: cluth doesnt work after bleeding

ello m8,take the clutch filler resivoir off and just leave the rubber cap in,, ,the clutch housing that u r bleeding from, should have about 3 bolts holding it on to the engine,, un do them ,dont take them out but undo them till they are holding in to the casing,, pump the clutch a few times untill u see the piston in the housing move,keep pumpin the clutch untill all the slack from the housing is gone, then do up the bolts ,and top up the fluid,, try this,, if nothing ,come bk and il take u threw step 2,, cheers now

Posted on Feb 28, 2009

  • 1 Answer

SOURCE: Clutch wont engage after kickstarter shaft installation.

The clutch lever must have been pushed in when i tried to install the push rod the first time so the push rod didn't get pushed in all the way.

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Posted on May 30, 2009

  • 1 Answer

SOURCE: new clutch plates and still will not pull itsself...help

hello did you do the center nut up to much as i did and i had the same prob as well it the one in the center of the clutch plate thanks karl

Posted on Sep 18, 2009

  • 3567 Answers

SOURCE: clutch push rod broke !!!

Chances are the prior owner installed some aftermarket springs that are too strong. This puts extra pressure on the push rod. Just pull the left and right cover of then remove the clutch assembly. put the new rod in from the left side then re-mount the left cover. Put the clutch back on then the right cover. The parts book shows a two piece push rod assembly. I wonder if a hardware store rod was installed because the factory rods are near impossible to find. The substitute rod probably couldn't handle the pressure and heat.
If not found elsewhere, google motorcycle salvage suzuki and see if you can find a used rod set.

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Posted on Sep 22, 2009

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1 Answer

2003 GSX600 Katana clutch will not disengage


Hi, Rotten_john you may have a parts, adjustment, safety switch or assembly issue for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Clutch won disengage on Katana
http://katriders.com/vb/showthread.php?t=123139
Suzuki GSX600F Service Manual
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Suzuki GSX 600F 2000 Owner Manual

Mar 07, 2017 | 2003 Suzuki GSX 600 F (Katana)

1 Answer

My M109's clutch was slipping, I inspected and replaced all drive and driven plates as well as the pressure plate, clutch springs (using heavy duty aftermarket springs) "push piece" and...


The two friction plates " off to the side " are the first and last plates to go into the clutch assembly. They are usually .005 to .007 thicker than the center plates. There's no extra link in the drive train that would mimic slippage. The springs are not likely to be the problem, especially since you have new ones. The usual sources for the problem are resistance in the drive train; on the stand, does the wheel turn freely in neutral? Is there any binding in the shaft drive? Another source is using the wrong lubricant in the gearbox. Use what Suzuki sells for the bike. I think the clutch is hydraulic on that bike. A bad slave or master cylinder could cause back pressure and not let the clutch fully engage.

Aug 01, 2011 | Suzuki 1190 RC8 Carbon Motorcycles

1 Answer

Clutch locked up on my 82 Suzuki dr250 I am at a loss what should I do.


your clutch is simply a stack of friction disks and metal plates. The friction disks are splined into the outer hub ring and alternate, one friction disk / one plate / one friction disk / one plate etc. It's very simple to free this up if it's locked up. remove clutch cover. If you are unsure which is your clutch cover, follow the clutch lever cable to the actuator arm. remove the cable from arm and all bolts holding the cover. as you pull out the cover, you will see the arm rotate that's because it's geared into an arm that is connected to the front plate of the clutch basket assembly. You'll see it as soon as you pull it off. now you'll be looking at a round plate with 6 bolts with springs underneath. when you arent pulling the lever, these springs are extended and push the friction disks and metal plates together, thereby locking the inner hub to the outer hub. The inner hub is connected to the crank, and the outer hub is connected to the transmission input gear. So, if pressed together by the springs, your engine running causes your bike to move. Pulling the clutch lever in pulls the spring tension off the plates and allows them to separate. This allows your engine to be disconnected from the transmission. If your plates are locked together you will remove them one by one if you can and lubricate between each plate and disk and reinstalling. Pay close attention to how it came apart. Reinstall bolts and springs reinstall cover, aligning the lever gear teeth with the front of the clutches teeth correctly. put it all together and see if you are okay now.

Nov 23, 2010 | 1988 Suzuki Rg 250

1 Answer

Im having trouble with my 2002 rm 250 clutchs... when i start to run the bike the cluth get like stuck or something and wildly releases at any moments and the bike runs off... its barely imposble to run...


  • A couple of things could be wrong. The clutch cable center wire could be frayed and catching up on the outer shell.
  • The clutch cable is bent or has been hit and crushed.
  • The outer and/or inner clutch hub is grooved and the friction plates are hanging up in the grooves.
  • You changed the gearbox oil and put in synthetic oil or an oil with "Special" additives. Synthetics can swell the cork on the friction plates and cause problems. Only use 10w40 motor oil in the gearbox.
  • A bad needle bearing at the pressure plate or on the shaft
  • The clutch was re-assembled incorrectly.
Go to the following website for an exploded view of your clutch. Please rate my answer. Thanks.
www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

Aug 25, 2010 | 2003 Suzuki RM 250

1 Answer

How many clutch plates are inside A 1990 suzuki dr650s




Reading from my manual (Suzuki Service Manual)

Primary drive gear (the clutch "basket")
Spacer
Clutch pressure plate
Clutch drive plate (has friction pads) x 6 of these alternating with...
Clutch driven plate (smooth) x 6 of these
Clutch drive plate (thicker with friction pads) x 1 of these to finish plates
Wave washer
Wave washer seat
Clutch sleeve hub then goes on with springs etc.

please check the site below, it has exploded views of the bike in all categories.

Cheers.

http://www.cmsnl.com/suzuki-dr650-s-1990-1991-usa_model15961/partslist/

May 09, 2010 | 1990 Suzuki DR 650 RS

1 Answer

2005 kdx 200 clutch not engaging properly


Assuming the clutch handle on the handlebar is adjusted properly, only three things will cause the problem.
  • Very dirty oil in the gearbox. The grit is causing the clutch to drag. Change oil, ride for an hour in the city then change oil again to flush out the grit.
  • Worn clutch lever (at gearbox). Lever is not moving the pusher far enough to fully disengage the clutch. A new lever would be needed.
  • Synthetic lubricant ( or oils with "special" additives), was put in gearbox. 10w40 motor oil should be used in the gearbox. Synthetics can swell the cork on the friction plates causing the clutch to drag. New friction plates will fix the problem.
The current amount of clutch drag is not enough to harness the power of an engine rev. That is why the clutch seems okay at higher revs. Please rate my answer. Thanks.

Jan 14, 2010 | 2005 kawasaki KDX 200

3 Answers

My clutch in my rm 250 wont disengage i know the pressure plate is moving but it still wont disengage?


If you put synthetic oil or an oil with "Special" additives in the gearbox the cork on the fiber friction plates may be swollen. The swelling can cause the clutch to stay engaged, Only use standard 10w40 motor oil in the gearbox. You will need new fiber friction plates if that is what has happened. Normally the only other three things that would cause the problem are a worn shift arm, a bent push rod and a badly worn cable.

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Oct 18, 2009 | 2003 Suzuki RM 250

2 Answers

Suzuki gsx600f clutch problem


if it is in gear for sure and it doesnt move even with the clutch engaged maybe you are missing a piece inside the clutch like the clutch boss spring. or possibly your plates are worn so much they wont hook up. or you are using a very poor grade of oil. Dont take my absolute word for all these solutions but these may lead to some problems like that.

Aug 16, 2009 | 1991 Suzuki GSX 600 F (Katana)

1 Answer

2008 Yamaha TW200 will not move when clutch released


Here are the possibilities > > Bent clutch push rod, missing push rod ball bearing or push rod, worn out actuator shaft cam, Missing friction disk (5), or pressure plate (4), totally worn out friction disks, clutch plates not installed in the correct sequence, extremely weak clutch springs, stripped teeth on the clutch hub, wrong clutch cable length (inner cable vs outer cable), broken shaft, bent then broken shift fork stems, broken slider gear dogs and a missing shift fork pin.

You didn't say if anyone had worked on the clutch or gearbox so I am throwing in nearly EVERYTHING possible that could create the problem. A little more background and most of the above can be ruled out. Get back to us.

Apr 22, 2009 | Yamaha TW 200 Motorcycles

1 Answer

Clutch basket


but it was not as deep as the original. Did the older bikes have a sallower basket. Mine is a 2005 and holds 8 fibers and 7 steel plates. I can't find any partd lists for the older bikes on the web. First a question. Are you using the original clutch fiber plates and friction disks or, did you get a new pack of plates and disks to go with the new basket. I'll explain my question below. The clutch on the 125 is sort of touchy. I tried various configurations, mainly using all steel drive plates, instead of the combination of steel and aluminum. I was only able to make it work properly using the OEM GG configuration. The 125 uses a different clutch than the larger bikes. (The 200's clutch basket has a different gear on the back, but otherwise it's clutch is the same as the larger bikes.) Make sure your replacement clutch disks & plates are not for the larger bikes. (I recently saw an ebay seller's auction that claimed to be a clutch rebuild kit for the GasGas bikes. It only had 7 friction disks. ) The original clutch for the 125 Gasser had a combination of aluminum and steel drive plates. The friction plates were all the same. The 2005 parts book lists them as being 3 iron disks and 4 aluminum disks. (In my memory, I thought it was 4 steel and 3 aluminum.) If you download and look at the parts book, http://www.gasgasmotos.es/rcs/manual...emotorec05.zip , the 125 clutch is on one of the last pages of the book. (page 48 of 50) BTW. I still have a new OEM GasGas 125 clutch pack in my stock; if anyone is interested. (side note: The clutch push rod for the 125 is only a few dollars. The clutch push rod for the larger bikes is in the $35 range.),,,

Nov 10, 2008 | 2007 Gas Gas EC 125

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