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Help Across Clutch Push Rod Problem

Discussion in 'Suzuki 250cc In-line 4's' started by PabloB, Mar 4, 2020.

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  1. PabloB

    PabloB Member

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    I have googled all over and can't find a definite answer to this problem.

    (clutch and changing gears before this was working fine)

    I removed the front gear cover to clean out 70,000 klms of crap. (found about 6 'o'rings from old chains) When I removed the cover the push rod fell out and I just slid it back in.(about an inch)
    Once I assembled everything I tried the clutch,first gear=stall. The push rod dose not wont to go into the clutch. I took it off again and noticed that the push rod goes in by hand about an inch and seems to hit solid metal.
    I have had it on and off and cannot work it out.
    Hope someone has some ideas.
    Paul
     
    PabloB, Mar 4, 2020
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  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    The push rod probably isn't seating onto the pressure plate of the clutch. Might need to pop the clutch cover and have a look.

    My bandit and gsxr have the same arrangement.
     
    Linkin, Mar 4, 2020
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  3. PabloB

    PabloB Member

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    would I need to replace the gasket?
     
    PabloB, Mar 4, 2020
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  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    If you are careful and lucky you can save the gasket. Otherwise order a few new ones, one to use and the rest for spares.
     
    Linkin, Mar 4, 2020
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  5. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Try spinning the engine over on the starter motor while keeping pressure on the push rod with your hand. This may allow the rod to drop into place.
     
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    Murdo, Mar 5, 2020
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  6. PabloB

    PabloB Member

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    thanks Murdo, I'll give that a try today and let you know.
    So I just crank it without starting ? in neutral i guess? Nooby here ! Any special way ?
     
    PabloB, Mar 5, 2020
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  7. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Don't start the engine, just turn it over on the starter so the rod can drop into the recess.
     
    Murdo, Mar 5, 2020
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  8. PabloB

    PabloB Member

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    Thanks guys, I was able to take the clutch side off and the rod then sat in the right place....
    But I still have no clutch (stalls in first) What is the best way to adjust everything now?
    Cheers

    ps: also installed new clutch cable.
     
    PabloB, Mar 5, 2020
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  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Andych, Mar 5, 2020
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  10. PabloB

    PabloB Member

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    Do you commission ? lol
    look's like I'm now a Premium Member :)
     
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    PabloB, Mar 5, 2020
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  11. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Nope... it helps pay for keeping the forum alive.. guys like @GreyImport and @kiffsta put not only time but money into making this the best forum on the Interwebs... so every little bit from Premium membership helps
     
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    Andych, Mar 5, 2020
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  12. PabloB

    PabloB Member

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    I downloaded the workshop but it states year 91-94. (I have a 95)?
    Also I wanted to know the clutch spring set bolts torque setting(which it doesn't state)?
    Paid $$ and still no answers...
     
    PabloB, Mar 5, 2020
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  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    It's likely a grey import so the year model will most likely be the year it was made compliant for Australia.

    Clutch springs are generally low torque, in the range of 6-10nm. Check the manual again, torque specs are usually listed at the beginning of each section or in the exploded views somewhere. I'm not familiar with the across or it's manual though.

    As for your $$ comment... this place is run by the goodwill of its members, the membership fee helps keep the lights on and people who are just after manuals and nothing else, out... there is a wealth of knowledge here amongst the members with no BS, so kindly check the attitude in at the door.
     
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    Linkin, Mar 5, 2020
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  14. PabloB

    PabloB Member

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    no attitude, I met the guy who started this site the other week and I am happy to help out ;)
    You know we get a bit stressed when we want something fixed.
     
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    PabloB, Mar 5, 2020
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  15. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Dont be concerned about the year model.. if you go to page 194 it gives you a guide on tightening torque for any bolts "NOT" listed in the previously.
    As long as you tighten them in the diagonal sequence shown and use the sizing chart you will be fine...
     
    Andych, Mar 6, 2020
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  16. PabloB

    PabloB Member

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    thanks so much
     
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    PabloB, Mar 6, 2020
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  17. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Does it stall immediately when you let the clutch out? Don't know that bike, but it might be a cutout sensor...sidestand, clutch/gear etc. Just a suggestion.
     
    Frankster, Mar 6, 2020
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  18. PabloB

    PabloB Member

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    My Bike:
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    thanks frankster,
    pull the clutch, into 1st = stall. Must have the adjustment way out.
    Was all working fine until I removed the clutch lever cover to clean, push rod fell out, dramas ever since.
     
    PabloB, Mar 6, 2020
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  19. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    There are instructions in the manual on adjusting the clutch, probably has changed with the new cable...
    I would have thought it wouldn’t even go into gear if the adjustment was that far out though..
    Have a look at the diagrams and make sure all the parts are in the right place, especially the thrust bearing etc..
    I don’t have the manual with me right now but I can look later on to see if anything jumps out as being obvious that might go wrong....
    As with most things it will be something silly that when you see it or fix it you will go....oh...yes.
    Happens to all of us.
     
    Andych, Mar 6, 2020
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  20. PabloB

    PabloB Member

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    that would be great if you could take a look for me, and yes, it probably will be a simple oversight or something staring me in the face.
     
    PabloB, Mar 6, 2020
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