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Author Topic: My DR 750 - Questions - Fixing the Clutch pressure Plate  (Read 1640 times)

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Offline Gérrard

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My DR 750 - Questions - Fixing the Clutch pressure Plate
« on: October 08, 2014, 01:18:25 pm »
Riding the bike last Saturday the clutch gave in. Got home and found the actuating arm(the one going into the clutch cover, that has the lever on it to which the cable connects) does not grip and push inside on something to release the clutch.

What is inside there that has come loose/strip/broke off ?
« Last Edit: October 11, 2014, 06:17:58 pm by jupiter »
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Offline Dux

Re: My DR 750 - Questions
« Reply #1 on: October 08, 2014, 04:19:36 pm »
http://www.cmsnl.com/suzuki-dr750-1989-sk_model13270/partslist/FIG-16.html#results

Clutch arm #22 slides into spline of shaft #20 , when clutch is pulled the shaft rotates and gear at the bottom of shaft #20 meshes with geared teeth on pullrod #18 and in so doing pulls pressure plate away from clutch plates .
So if you have no clutch at all I would suspect the gear on shaft or pullrod has been damaged .

Is this what you were looking for ?
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Offline Gérrard

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Re: My DR 750 - Questions
« Reply #2 on: October 08, 2014, 09:16:38 pm »
Thanks, now I understand how it works and it would seem its the pinion gear that stripped/failed. Hope to strip and have a look this weekend.

Thanks for the link. had been wondering where I was going to get parts.
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Offline Wild Hearted Son

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Re: My DR 750 - Questions
« Reply #3 on: October 08, 2014, 09:34:15 pm »
had been wondering where I was going to get parts.
also try here http://www.dr-big-shop.de/
&
surprisingly a lot of parts are still available over the counter from Suzuki
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Offline Gérrard

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Re: My DR 750 - Questions
« Reply #4 on: October 10, 2014, 08:56:23 pm »
OK, so I got the manual. Par 1 says this is a manual for an experienced mechanic to use as a guide.  Right.

1 Remove the engine from the bike
1.1 Disassemble the engine

2 Re-assemble the engine in reverse order
2.1 instal the engine in the bike

 :imaposer:

So I need to remove the clutch cover. There's this bolt. What does it do ? Do I remove it first or just leave it there ? What's going to fall apart when I take the clutch cover off.
...dis nooit te laat om n happy childhood te he nie !

Build a sidecar they said. It will be fun they said. Ja-nee !
 

Offline Dux

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #5 on: October 11, 2014, 06:29:28 am »
On the 650 that is an oil sightglass , on the 750 you would probably pour in oil until it comes out of the hole then you know there is enough in the engine .
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Online Tommy Transalp

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #6 on: October 11, 2014, 06:51:02 am »
Jup.... Ping Dr BIG (Gerald)... he's been there with the clutch job. I turned a thrust bearing pocket out for him after it was aluminium welded. Seems this is a fairly common problem on these models. (maybe because of the high torque?)  :thumleft:
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Offline Gérrard

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #7 on: October 11, 2014, 07:46:15 am »
On the 650 that is an oil sightglass , on the 750 you would probably pour in oil until it comes out of the hole then you know there is enough in the engine .

 :thumleft: It has a dipstick

Jup.... Ping Dr BIG (Gerald)... he's been there with the clutch job. I turned a thrust bearing pocket out for him after it was aluminium welded. Seems this is a fairly common problem on these models. (maybe because of the high torque?)  :thumleft:

He responds a bit slow. By the time I hear from him I want to ride again  :dousing:
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Offline chopperpilot

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #8 on: October 11, 2014, 08:30:44 am »
On the DR 650 that type of bolt covers an oil channel, used when connecting an oil pressure gauge to check oil pressure. If it is on the cover I doubt if you even have to remove it to get the cover off.


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Offline chopperpilot

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #9 on: October 11, 2014, 08:33:21 am »
It sits at a different location on the DR 650 SE ('96 till current), but it's the identical bolt.


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Offline lecap

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #10 on: October 11, 2014, 11:39:32 am »
It sits at a different location on the DR 650 SE ('96 till current), but it's the identical bolt.


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Yep. The plug in the oil gallery on the 650SE engine sits underneath the engine towards the front and I think in the right crank case half. Most people never realise it's there. Which might be a good thing :lol8:
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Offline DR BIG 750

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #11 on: October 11, 2014, 01:54:40 pm »
sorry missed it someone threw a beer at me and i had a sore head, are you sorted yet. I have had some fun with these clutches. dont need to pull out the motor all can be done in the frame. let me know if i can help..
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Offline Gérrard

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #12 on: October 11, 2014, 02:09:05 pm »
sorry missed it someone threw a beer at me and i had a sore head, are you sorted yet. I have had some fun with these clutches. dont need to pull out the motor all can be done in the frame. let me know if i can help..

 :thumleft: Like I said  :lol8: ... just removed all the parts to get to the clutch cover and drained the oil. Geeze, it takes a shit load. Will remove the cover just now.

Just for interest... what is the oval cover under the engine on the right side of the crank case ? (like the exhaust or intake valve covers on singles)

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Offline Gérrard

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #13 on: October 11, 2014, 02:30:39 pm »
Clutch cover won't come off (easily after I moered it with a mallet)

Do I also have to remove that big bolt shown above(there's also a little bolt above it).
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Offline Gérrard

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #14 on: October 11, 2014, 03:09:52 pm »
1. I love his. Working on a bike and having no idea what I'm doing... OK a little
2. Dummy mechanic.
3. Clutch cover off (also needed to remove the little bolt in the middle  ::) Everything looks very nice in there  :thumleft:
4. The culprit... the little pull thingy is ISM. What happened ? What am I looking at and what's it properly called.

What do I do next  ???
...dis nooit te laat om n happy childhood te he nie !

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Online Bensien

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #15 on: October 11, 2014, 03:20:26 pm »
That’s the push pin. Just check that is the only thing wrong and not just a symptom of a bigger problem like warped plates or notched hub splines and housing grooves that were putting strain on the pin.
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Offline DR BIG 750

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #16 on: October 11, 2014, 03:55:57 pm »
have you got any clutch at all or dragging or slipping. checck the press plate where pin goes throught some times it wears after all the km you have probablly done. and rememeber when you put the thrust washer back. bearings against the pin and not the the alloy plate. wil keep watching the thread while i am enjoying the LIONS whip vrystaat
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Offline DR BIG 750

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #17 on: October 11, 2014, 03:59:08 pm »
the plate has a sieve in there to stop the big pieces of broken valves etc ;D going up stream
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Offline DR BIG 750

Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #18 on: October 11, 2014, 04:01:40 pm »
pull the plates out check them all, maybe rough up the plates they do glaze after years of use, but again do you have any clutch
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Offline Gérrard

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Re: My DR 750 - Questions - Removing the Clutch Cover.
« Reply #19 on: October 11, 2014, 05:22:33 pm »
Right  :-\

1. Pull out the clutch plates and find lots of bits and pieces of metal and paste
2. Crab does abit of cleaning up
3. What we manage to fish out the clutch housing


...dis nooit te laat om n happy childhood te he nie !

Build a sidecar they said. It will be fun they said. Ja-nee !