1981 GS450 - shifting gears

[ssco156]

I tried to go for a ride this morning but once I took off couldn't shift from first gear to neutral or second gear. I had noticed that I was having trouble finding neutral these past few weeks but all else seemed fine. I can shift to second and third gear with the engine not running. I have also noticed that pushing the bike in neutral is much easier than pushing it in first gear with the clutch pulled in. Is this an indication of a clutch problem? Any help will be much appreciated.

[Rob S.]

I have also noticed that pushing the bike in neutral is much easier than pushing it in first gear with the clutch pulled in.

That part sounds normal to me.

Do you have instructions for adjusting your clutch?

[ssco156]

I've got the Clymer manual but that's about it. Could it be just a clutch adjustment?

[pete]

Definitely check clutch adjustment first, but another possibility is that the rose/heim joints in the gear shift linkage are flogged out giving too much free play.

I actually rebuilt my engine because I didn't check this, and thought I had a gearbox problem. Yes, I did. Imagine how much a fool I felt when I found everything in spec, reassembled, then discovered the excess free play

The linkage design means if there's too much free play, shifting in to first and then down shifting from the higher gears will result in the gear lever impacting the shift linkage shaft before engaging the gear, meaning getting stuck in neutral or not being able to down shift.

[ssco156]

Actually, you might be right about the linkage. Someone pointed out to me that it had too much free play some time ago, but me being the type of not fixing things which are not broken just let it go. Maybe the time has come to do something about it but I'll definitely see if the clutch needs adjusting before anything else. Thanks for your input.

Definitely check clutch adjustment first, but another possibility is that the rose/heim joints in the gear shift linkage are flogged out giving too much free play.

I actually rebuilt my engine because I didn't check this, and thought I had a gearbox problem. Yes, I did. Imagine how much a fool I felt when I found everything in spec, reassembled, then discovered the excess free play

The linkage design means if there's too much free play, shifting in to first and then down shifting from the higher gears will result in the gear lever impacting the shift linkage shaft before engaging the gear, meaning getting stuck in neutral or not being able to down shift.

[cowboyup3371]

Recheck your adjustment first before doing much else

[steve murdoch]

Schematic of the S version.
Which model 450 do you have?

https://www.ronayers.com/oemparts/a/suz/50d3f07bf8700230d8b4b8a8/gear-shifting

[ssco156]

Schematic of the S version.
Which model 450 do you have?
https://www.ronayers.com/oemparts/a/.../gear-shifting

It's supposed to be an S version even though I bought it without the fairing. This could have been removed by a previous owner. I've attached a photo of the bike. I have removed the shifter/pedal linkage and the two bearings in the link arm (no28 in the schematic) are shot. Could that be the problem?

[Gorminrider]

I've got the Clymer manual but that's about it. Could it be just a clutch adjustment?

Can't have too many manuals...
I hope the link is still good but You can get the real shop manual by vgplay here:

https://www.thegsresources.com/_forum/showthread.php?258200-GS450-Official-Service-Manual-PDF

[steve murdoch]

It's supposed to be an S version even though I bought it without the fairing. This could have been removed by a previous owner. I've attached a photo of the bike. I have removed the shifter/pedal linkage and the two bearings in the link arm (no28 in the schematic) are shot. Could that be the problem?

That is what Pete was referring to when he said the rose/heim joints could be shot.
They can be replaced. You may find them cheaper elsewhere. Also make sure they are the correct ones for your set-up.
This is strictly for reference.

https://www.z1enterprises.com/m6-x-1-0-stainless-steel-spherical-rod-end-heim-joint-female.html

[ssco156]

Definitely check clutch adjustment first, but another possibility is that the rose/heim joints in the gear shift linkage are flogged out giving too much free play.

I actually rebuilt my engine because I didn't check this, and thought I had a gearbox problem. Yes, I did. Imagine how much a fool I felt when I found everything in spec, reassembled, then discovered the excess free play

The linkage design means if there's too much free play, shifting in to first and then down shifting from the higher gears will result in the gear lever impacting the shift linkage shaft before engaging the gear, meaning getting stuck in neutral or not being able to down shift.

My joints are definitely gone. I'm sending a photo showing my assembly with what I presume are the joints we're talking about marked in red. Do you think I should go for new parts or try sourcing a used complete assembly?

As a sideline, I see you're in Queensland. I've got some good memories of Australia, spent thirteen years in Melbourne in the 80s and 90s.

[ssco156]

That is what Pete was referring to when he said the rose/heim joints could be shot.
They can be replaced. You may find them cheaper elsewhere. Also make sure they are the correct ones for your set-up.
This is strictly for reference.
https://www.z1enterprises.com/m6-x-1...nt-female.html

l

Thanks for your help. What would be involved in removing and replacing the old joints? Would this require a press?

[pete]

Apologies, haven't logged in this week!

Yep, those are the rose/heim joints that are the problem.

I simply used a dremel to grind off where they'd been peened at the rear to enable replacing them, and any suitable rod end, rose joint, or heim joint that fits the M6 threads should be fine. Just be careful with dimensions as the body on some of the rod ends on eBay are too long and you won't be able to fit the jam nut back on as well.

The rod ends I replaced mine with are simply bolted to the gear lever and splined part with M6 nuts and bolts.