Expert advice needed - Clutch on an RM250T

[Graeme M]

OK Suzuki gurus. Today I replaced the whole clutch on my 1980 RM250T. I replaced everything, even the pushrods. One curious thing is that the new rods, which are correct according to Partzilla, are different to the originals. The originals have one rounded end and a flat end, whereas the new ones are rounded at both ends.

It seems the original part number supersedes to a new number so I assume the design was changed.

Now, my question. Is the ball bearing still required with the new rods? I have used it but the adjuster now stands proud of the locknut by several mm more than it did, and looks like it'll come close to rubbing on the clutch cover. I have a vague recollection that the ball was not required with the new design rods, is that true?

[Tim754]

Graeme, I recall the very same change on a Suzuki two stroke agi bike, It did have the ball deleted as per the replacement memorandum  . That dual rounded rod had obvious hardening on the ends. Most likely yours will appear the same or is completely hardened.
I don't pretend to be an expert but offer this from experience. Cheers

[crs-and-rms]

is the new push rod longer than the old one

[Graeme M]

Haven't directly measured them, but my guess is yes. I suppose if they measure out as longer by about half the width of the ball, my question is answered...

[crs-and-rms]

yes if they are the same lenth leave the ball in if the new rod is longer it should be the same lenth as the old rod and the ball together

[oldfart]

Graeme ....  part # 23111-39101  was only used on Rm 250 N/T  Rm 400 N/T  plus Rm 465 . In Suzuki wisdom they have crossed it over to road bike's and hence the part you have now being  23111-15501 .
For me had the same problem when I rebuilt mine and decided to stay with old rods and ball as the new did not work and had the same clearance problems. 
Part # = 23111-15501
Part Description = ROD,CLUTCH PUSH,LEFT
Model Count = 33
GR650D 1983 650 GR650 TEMPTER STREET
GSF600SY 2000 599 GSF600S BANDIT STREET
GSX-R1100G 1986 1052 GSX-R1100 SPORT
GSX-R1100H 1987 1052 GSX-R1100 SPORT
GSX-R1100J 1988 1052 GSX-R1100 SPORT
GSX-R1100WP 1993 1074 GSX-R1100W SPORT
GSX-R750G 1986 747 GSX-R750 SPORT
GSX-R750H 1987 747 GSX-R750 SPORT
GSX1100FJ 1988 1127 GSX1100F KATANA 1100 SPORT
GSX1100FK 1989 1127 GSX1100F KATANA 1100 SPORT
GSX1100FL 1990 1127 GSX1100F KATANA 1100 SPORT
GSX1100FM 1991 1127 GSX1100F KATANA 1100 SPORT
GSX1100FN 1992 1127 GSX1100F KATANA 1100 SPORT
GSX1100FP 1993 1127 GSX1100F KATANA 1100 SPORT
GSX550ED 1983 572 GSX550E STREET
GSX550LD 1983 572 GSX550L STREET
GSX600FW 1998 599 GSX600F KATANA 600 SPORT
GSX600FX 1999 599 GSX600F KATANA 600 SPORT
GSX600FY 2000 599 GSX600F KATANA 600 SPORT
GSX750FW 1998 748 GSX750F KATANA 750 SPORT
GSX750FX 1999 748 GSX750F KATANA 750 SPORT
GSX750FY 2000 749 GSX750F KATANA 750 SPORT
GS550ESE 1984 549 GS550ES STREET
GS550ESF 1985 549 GS550ES STREET
GS550ESG 1986 549 GS550ES STREET
GS550LF 1985 549 GS550L STREET
GS550LG 1986 549 GS550L STREET
RM250-N 1979 246 RM250 OFF ROAD
RM250-T 1980 246 RM250 OFF ROAD
RM250-X 1981 246 RM250 OFF ROAD
RM400N 1979 417 RM400 OFF ROAD
RM400T 1980 417 RM400 OFF ROAD
RM465X 1981 465 RM465 OFF ROAD

[Graeme M]

Hmmm... I measured the new and old rods and they seem to be pretty much identical overall length which seems strange. Now I'm not too sure which way to go!!

Also, should the clutch push piece rotate smoothly on the thrust bearing? Once it's got some tension on it it's fairly rough and that seems to be due to the machined surface of the push piece bearing face. I guess it doesn't matter, I've just ordered new parts rather than worry about whether the old ones are any good...