Clutch cover replacement problem

[Thomasgrier1]

New to forum with 81 gs850L. Been working on for several months after it sat for several years ( mains things obviously carbs and brakes). Had running good for about 500 miles so thought I would work on cosmetics to make it look nice ( major clean up with lots of wd40 and #0000). The absolute last thing I wanted to do was clean up the nasty clutch cover ( 1500 sandpaper and LOTS of aluminum polish). I had no slippage issues at all and clutch operated perfectly so wanted to just take off cover, clean up, and put back on. So here is the issue, once put cover back on (with new gasket) and the actuator back on, the clutch lever has no pressure and won’t engage the clutch. It’s not the cable or the actuator as they try to spin that rod that stays on the cover ( don’t know name of it) but somehow not linking up with the rod that runs out through the middle of the clutch basket. Tried reinstalling several times with different locations of the splines but no luck. Can anybody give me an idea of how stupid I am?

[Thomasgrier1]

Didn’t mean to post under bike of the month but further proof of my stupidity ( and that without any beer!).

[rphillips]

Well, looks like you're learning... Lots more to come.. Welcome

[Cipher]

New to forum with 81 gs850L. Been working on for several months after it sat for several years ( mains things obviously carbs and brakes). Had running good for about 500 miles so thought I would work on cosmetics to make it look nice ( major clean up with lots of wd40 and #0000). The absolute last thing I wanted to do was clean up the nasty clutch cover ( 1500 sandpaper and LOTS of aluminum polish). I had no slippage issues at all and clutch operated perfectly so wanted to just take off cover, clean up, and put back on. So here is the issue, once put cover back on (with new gasket) and the actuator back on, the clutch lever has no pressure and won’t engage the clutch. It’s not the cable or the actuator as they try to spin that rod that stays on the cover ( don’t know name of it) but somehow not linking up with the rod that runs out through the middle of the clutch basket. Tried reinstalling several times with different locations of the splines but no luck. Can anybody give me an idea of how stupid I am?

Pg 87 https://gsarchive.bwringer.com/mtsac.../gs/GS1000.pdf
I assume the orientation is correct and cannot imagine Suzuki engineers would deviate from one bike to another.

[Phil]

Welcome Thomasgrier1. I'm about as experienced as you are.
I won't be of any help to solve the issue but...
1. the fiche and parts name may help you describe the situation: https://www.partzilla.com/catalog/su...gs850gl/clutch
2. have you removed any other part but the cover?
3. when you say "won't engage" do you mean the clutch is engaged (bike on central stand, in any gear except neutral the rear wheel won't turn) and you can not disengage the clutch (pulling the handle clutch lever does nothing) it or the other way around (the rear wheel turn regardless which gear is selected)?
4. would a picture / video help?

[Phil]

A quick search pointed me to these related threads:

https://www.thegsresources.com/_forum/forum/technical-forums/old-technical-info-forum/34627-clutch-won-t-disengage

https://www.thegsresources.com/_forum/forum/technical-forums/-4-cylinder-engine-drivetrain-clutch/51891-clutch-help

https://www.thegsresources.com/_forum/forum/technical-forums/general-maintenance/51286-clutch-cable-question

Hope it helps.

[Thomasgrier1]

Thanks for trying to help. Am I an idiot? The answer is yes I am. I adjusted the clutch cable and issue is gone. I saw the actuator and cable working fine and so originally just replaced as it was prior to cover removal. had it where I wanted it one didn't think taking cover off would affect it. It did but now fixed.