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My clutch release screw assembly is loosing its marbles

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  • #1

    My clutch release screw assembly is loosing its marbles

    For those of you who are wondering, it is part #23 on the various part diagrams, Suzuki part#23200-31300 SCREW ASSY CL R.

    And I have a couple of questions about this beast.

    This is my grandson's bike and it the last thing I have to fix after the chain jumped and busted up a lot of stuff, including the LH clutch push-rod and engine-sprocket cover.

    So I was taking the old clutch screw assembly of the broken cover when it unexpectedly unscrewed it self and dropped it's ball-bearings all over the place. Luckily, I was doing this over a tray and got them all. It seems that the inner-race has gotten wollered-out (technical term there) and no longer captures the bearings.

    I am assuming that it is NOT supposed to come all apart like that?
    I am assuming that the inner race IS supposed to hold the bearings behind it and not let them fall out?

    Just want to be sure before I spend even more money on yet another part for this bike.

    ALSO, since the LH push-rod, part#21 on the clutch diagram, broke I read that I should pull the oil seal and remove any left-over pieces. Is there any trick to that or can I just pry it out with a screw-driver? Again, last thing I want to do is make a 1/2 day job into a 3-week ordeal.

    Sorry for the long post (and yes I did RTFM the service-manual that I have--not very helpful ).

    TIA
    Bill W
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  • #2
    It shouldnt just fall apart that easy..if it looks really worn id replace it..i think it was like $40 with shipping when i repleaced mine

    Comment

    • #3
      Originally posted by wildbill001 View Post
      For those of you who are wondering, it is part #23 on the various part diagrams, Suzuki part#23200-31300 SCREW ASSY CL R.

      And I have a couple of questions about this beast.

      This is my grandson's bike and it the last thing I have to fix after the chain jumped and busted up a lot of stuff, including the LH clutch push-rod and engine-sprocket cover.

      So I was taking the old clutch screw assembly of the broken cover when it unexpectedly unscrewed it self and dropped it's ball-bearings all over the place. Luckily, I was doing this over a tray and got them all. It seems that the inner-race has gotten wollered-out (technical term there) and no longer captures the bearings.

      I am assuming that it is NOT supposed to come all apart like that?
      I am assuming that the inner race IS supposed to hold the bearings behind it and not let them fall out?

      Just want to be sure before I spend even more money on yet another part for this bike.

      ALSO, since the LH push-rod, part#21 on the clutch diagram, broke I read that I should pull the oil seal and remove any left-over pieces. Is there any trick to that or can I just pry it out with a screw-driver? Again, last thing I want to do is make a 1/2 day job into a 3-week ordeal.

      Sorry for the long post (and yes I did RTFM the service-manual that I have--not very helpful ).

      TIA
      Bill W
      Originally posted by firefighter313 View Post
      It shouldnt just fall apart that easy..if it looks really worn id replace it..i think it was like $40 with shipping when i repleaced mine
      Actually... yes, they will fall right out.

      Yes, this is normal when the grease is allowed to dry out or is non existent.

      Part of the regular maintenance of these bikes is for that assembly to be removed, cleaned, liberally applied with water resistant grease, and put back together for a smooth clutch. Besides a damaged clutch cable, it's the second most common reason people have "hard" clutches... meaning it takes a lot of pressure to pull the clutch in.

      To put it back together is simple enough...

      Start with cleaning everything.

      Use marine grade grease on the insides, a lot of it.

      The grease will hold the bearings in place long enough for you to carefully put the insert back inside, and bend the tabs to hold it in place. Every hole should have a bearing in it.

      Insert the worm gear correctly and your all set.

      Krey
      93 750 Kat



      Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

      "I've done this a thousand times before. What could possibly go wron.... Ooops!"

      Comment

      • #4
        Well, let me try to clarify a bit. The bearings go through the holes in the inner-race. so they will eventually work their way out of the whole assembly as you put the adjusting arm back in place. At that point, it seems that no amount of grease will hold them in place.

        Bill W.

        Comment

        • #5
          Originally posted by wildbill001 View Post
          Well, let me try to clarify a bit. The bearings go through the holes in the inner-race. so they will eventually work their way out of the whole assembly as you put the adjusting arm back in place. At that point, it seems that no amount of grease will hold them in place.

          Bill W.

          I understand what your saying, but your analysis is incorrect.

          When assembled, they will have no where to go in the process of normal use. The worm gear does not move far enough to allow for them to come out if they are properly positioned when it's inserted fully.

          The insert with holes in it is not to hold them securely, it's only a loose seat that positions them for when the worm gear is inserted.

          Krey
          93 750 Kat



          Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

          "I've done this a thousand times before. What could possibly go wron.... Ooops!"

          Comment

          • #6
            Hmmmm....Ok, so it is an exercise in patience. I'll go give it another try and see if I can get it together.

            Thanks!

            Bill W

            Comment

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