1980 GS1100 (Square headlight) clutch never fully disengages

[GabrielGoes]

As the title states, no matter how i set the slack on the cable, when i pull in the clutch all the way in first gear and give gas, you can feel the bike lurch and try to move forward. This also makes finding neutral impossible unless you shut the bike off.

Any quick plan of actions anyone can think of? the bike sat for 4 years or so. It sounds like to me they're sticking and i have to take the fiber disc's out and at least separate them and add some fresh oil unless anyone has any other ideas?

[Grimly]

Is the clutch actuating lever at the engine end getting full movement? Not unknown for them to be a spline too under (courtesy of the PO). They should be a spline over-centre.

[GabrielGoes]

Is the clutch actuating lever at the engine end getting full movement? Not unknown for them to be a spline too under (courtesy of the PO). They should be a spline over-centre.

-Thanks for that tip, i checked and it certainly is having its full range of motion.

-Now this is the stuff that drives me nuts... i took the clutch out and inspected every single spring and clutch disc with a micrometer and before even doing so they all looked brand new. Sure enough they are all 3.00mm(fiber) and 2.00mm(steel) zero discoloration and warping. i brake cleaned all the fibers and dried them off with an air gun and let sit. now theyre soaking in JASO oil as we speak. all the fibers said FP 492 on them and they don't look factory.

-The hub itself had NO grooves in it, nice and smooth all around.

-The only thing i noticed was the clutch hub nut was loose so i re-tightened that one and bent the tab over it.

-There's honestly NO tell tale sign as to why the clutch would be dragging and behaving the way it does. We'll see once i put it all back together.... stuff drives me nuts man as long as i've been doing this, there's always such a pain in the butt issue like this. I will try known good OEM springs i have. perhaps the springs are too hard is my guess they're Barnett's or something

[rphillips]

Do you remember how many plates are in there, should be 9 and 9. later models had 10 steels, if somebody got confused and put 10 in yours, that would make pressure plate need to move more to completely release. Just trying to think of what could be possible.

[Don R]

Sometimes the kind of oil in it will make them stick, sitting will do it also, I used to tie the lever back on my KZ when it was parked. Riding it is a good way to get them going.

[zuluwiz]

As I reread this again, the one thought that keeps popping into my head is: the clutch cable is stretching. Now maybe it's not a problem with the cable, but that would be the easiest thing\ to fix and the cheapest Putting a new clutch cable on would increase your peace of mind, and if thats not the problem at least you have a spare cable.

[GabrielGoes]

-I checked and sure enough the springs that were in there were extremely stiff! I put oem ones in there (red paint usually dabbed on the oem ones btw) and soaked the clutches in proper oil and now she behaves but the issue now is: the clutch line has to be completely adjusted to no slack making the clutch pull extremely hard as well.

-Since these fibers are not OEM and seem to all be 3.00mm where as the OEM is a few hairs more narrow, this is making the clutch behave like an "extra plate" kit

-The next plan of action is to use 3 heavy duty springs by themselves, and that along with the aftermarket fibers, I believe this should get the clutch to behave normally with the appropriate amount of slack. IF the 3 HD springs are not enough to keep the pack together then i'll go back to the OEM Springs but i'll have to shim them to release some tension

[Grimly]

Something backwards there - aftermarket clutch springs are usually chosen for their extra strength - whether necessary or not.
Along with many others on here, I've got currently excellent results from using 3 OEM (not old ones, but new) and 3 HD staggered alternately. The clutch, with its new fibres and mixed springs is a joy to use.

[GabrielGoes]

Yeah mate the clutch only operates properly when the lever is adjusted all the way out (no slack).

I have a feeling the thick aftermarket fibers and combination of the HD springs is making this clutch not want to disengage properly.

I used 3 hd and 3 oem springs that I squished with heat to shrink and it works better now.

I think the only way for me to get proper feeling is to exchange fibers to oem or EBC and something other than what's in it. Could be caltric or something I don't know but clutch is rubbish mate