550 clutch push rod ball size

According to the workshop manual my bike is missing a steel ball that goes between the push rod (arrow in photo) and the clutch spring plate pusher , anyone know the diameter

Take a look at the link below. It looks like that ball is 3/8" diameter. Ed

www.kawasaki.com/Parts/PartsDiagram/134979/1982/KZ550-A3

Thanks Ed

The only way I can fit the 3/8 ball is if I shorten the pushrod 3/8.. Which doesn't seem right.
I'm starting to think something changed with the KZ550H1 (1982GPZ550) and is not mentioned in the FSM, ether a shorter pushrod or they omitted the ball
Clutch worked fine before I pulled motor apart and found there was no ball fitted
Both the pushrods I have are 270mm long which are the correct length for the 550 according to APE's pushrod spec's.
The engine side cover that houses the clutch actuator is specific to the1982-83 gpz550 (KZ550H1-2) models only .
I need to replace the pushrod as both have some decent grooves worn into them.

The pushrod is usually not visible on that end (clutch end). The oil seal stops if from migrating inward. But, if pushed, the pushrod can go completely through to the other side as long as the ball, mushroom, pressure plate are not in place.

You've probably seen this diagram before, but it shows how much room there is from the end of the rod to the clutch hub shaft end. Normally if you pull the mushroom and ball, you can't see the end of the pushrod.

The pushrod is 270mm long total.
The pushrod is 8.0mm diameter along its entire length.
The middle section of the pushrod is aluminum.
Each end is made of steel, and the steel section is 36mm long.
When the clutch is fully assembled, the pushrod sticks out of the sprocket side, from the oil seal, by about 65mm.

Set the rod so about 65mm sticks out on the sprocket side, and see if you can get the ball and mushroom in (if you have a ball). Notice in the diagram they show the pushrod ends right at about the place that the bore gets wider for the ball. See (with flashlight maybe) if you can tell if the end of the pushrod is right there (when there is about 65mm sticking out of the sprocket side).

I have both 81's and an 82 motor, and I have never noticed any difference in the rod, clutch, or actuator. The covers look different cosmetically, but I think they can be interchanged. All Gpz550 engines use the 1981 D1 crankcase and transmission cover, so the distance through the motor would be the same. The clutches are the same. So I *think* the pushrods would have to be the same.

that photo in my first post was just me asking abiut the ball, the pushrod is loose, it goes further back.
I did my head in spending a few hours trying to figure out what was goi going on trying two sprocket covers and actuators as well as 3 diferent clutch packs and baskets to no avail.
with the ball in and the clutch springs torqued down the push rod sticks out to far and the sprocket cover wont bolt down. its got around 10mm to go befote it touches the cases.
If i remove the clutch spring bolts and bolt the sprocket cover down i end up with clutch spring plate sitting around 10mm (3/8") off the clutch plates.
With the ball removed everything bolts together nicely with around 60 thou play with the adjuster backed right off.
Its got me stuffed.

Put the ball/mushroom back together and torque down the clutch pressure plate and measure how much rod is sticking out on the sprocket side. If it's about 65 mm, then the problem is most likely on the sprocket side.

Do you have any photos of how the actuator is assembled, That sounds like where the problem is. Loosen the actuator adjustment locknut and make sure the adjustment is all the way out. That could get you 10mm.

In other words, looking at the sprocket cover, loosen the locknut (D) and turn screw (C) clockwise all the way, but not tight.
gpzweb.s3-website-us-east-1.amazonaws.com/ClutchReleaseMech.GIF

yes, clockwuse all tbe way to backoff the clutch adjuster (B is is wound all the way into C)
I removed lock nut D and can move C in and out roughly 60 thou
The cable is not connected so its not affecting the results.
Im at work so will have another go at it when i get home.

Computer is dead so I can't post photos at the moment

So with the mushroom pusher,-ball and clutch buttoned up the push rod sticks 80mm out of the case.
Pushrod 270mm
3/8 ball 9.5mm
Pusher. 31mm

Alright, I dug out another spare motor and measured the clutch rod protrusion on the sprocket side. That one came up as 66 mm.

So now we have to figure something is different on your clutch or motor.
I'm not sure if I have a 550 clutch mushroom laying around. One from a 650/750 might be longer. ..maybe someone swapped one of those in. Although, 31 mm sounds about right.

Let me see if I can find one.

Just to confirm that 80mm is from the case flange the trans cover bolts to.
I just refitted the cover and I get 65mm protrusion from the oil seal on the trans cover.
That sounds correct if where measuring from the same spot.

I found a clutch, pressure-plate, and pusher in a box... yay.

Yup, pusher is 31 mm.

The clutch pack stack height (7 disks, 6 metal plates) is 33 mm.

I don't have any clutch covers opened up on any motors right now. That will take some doing. I think the most likely one I have that I might be able to crack open is a 550C Ltd motor. Before I do that, though, can you confirm that you can see all the way through the pushrod hole so we know for sure there isn't something in there.

EDIT: I just saw your last post. I'm measuring from the oil seal. 65mm sounds good.
I'm glad I didn't open a clutch cover!