80 GS850G Clutch, or lack thereof

[Mekanix]

Seems like the pressure plate is getting stuck on top of the basket.

[Seana23]

Have you checked for burrs.on the clutch basket, inside and outside?

Xxx

[PaGS850]

okay... thinking it may be something else, because the old clutch still looks like it has plenty of meat.

correct me if I'm wrong...
the outer basket is connected to the engine, and the inner basket is connected to the rear wheel via the tranny and the shaft.

I can turn the inner basket with the bike in first gear. Is this normal or do I have a drive train or tranny problem?

[PaGS850]

ok, got the basket apart, inside grooves are checkered. Will a clutch from a GS 850 L fit my GS 850 G?

[Mekanix]

That basket doesnt seem bad enough to cause your problem.

The outer is driven by the crank. The inner drives transmission. Your probably stuck between 1st gear and neutral. Try another gear while you rotate the tire and you should see the inner basket move as well.

When you took the outer pressure plate off after it got stuck was the outer plate stuck on top of the basket? or was it still down on the disks?

[PaGS850]

That basket doesnt seem bad enough to cause your problem.

The outer is driven by the crank. The inner drives transmission. Your probably stuck between 1st gear and neutral. Try another gear while you rotate the tire and you should see the inner basket move as well.

When you took the outer pressure plate off after it got stuck was the outer plate stuck on top of the basket? or was it still down on the disks?

Got it on the sidestand so I didn't have to drain the oil again. I just ordered another clutch assembly for $25, seemed like the best idea. Just got the baskets off, finally got a buddy to weld a rod to one of the old steel plates.

The top fiber plate was stuck to the outer plate. there was also grooves from the springs (see pic)

[Seana23]

ok, inside grooves are checkered........

i got it.... I got it.....
....i got it....
...........i.got it....
....................
..................i got it!

Xxx

[PaGS850]

You didn't get it, put in the new clutch basket with the new springs and plates, no differance. Arm on top rotates freely about a quarter turn, then a dead stop, Ripped it apart again and put in the plates and springs that came with it. No Difference.

It appears like the pressure plate isn't being pulled off the plates, however that would mean the clutch was engaged all the time. Haven't tried that yet.
I pushed on the arm and it doesn't budge at the stop.

Going to put it back together again and see if its engaged all the time, or perhaps it just needs to get to temp before working. Just thought I'd fish for answers in the meantime.

I would almost think its a tranny or driveshaft problem if it wasn't for the limp clutch. HELP.

[Seana23]

Oh.

...i thought i got it.

But i didn't.


X

Erm, you have got the required number ov plates in there havent you?


Did I get it?
.........

[Mekanix]

Going with what your saying, IF there were too many plates then the arm would rotate and pull the pin all the way to the stops and still wouldn't have pulled the pressure plate off of the clutch.

Its as if the pressure plate was too far out from the engine

Could it be that the clutch basket is spaced too far away from the engine from a bad washer behind it or not meshing properly with the oil pump gear?

Does the clutch have any in and out play ? Try assembling it and give it a good push in and see if it pop's. Then put the cover on and try moving it.


IF it does work when you try it, you might find that the clutch has poped itself back into place again and its only a matter of a few clutch lever pulls for it to stop working again.

I'm going to the manual again

Edit, ok back, The manual show's a large bearing just behind the clutch with a ring around it to lock it into the case so I don't see that moving unless the ring isn't there. Also the shaft has a shoulder that back's up against the bearing so it would have to be a bearing failure for this theory to be plausible.

[PaGS850]

Maybe not the clutch

Got it back together and it seems a have a clutch, at least the lever is no longer limp. Started it, clunks into gear, but doesn't move. Put it on the centerstand, started it, put it in gear(s), rear wheel still does't move. rotated the rear wheel by hand, verified that it turns under the boot at the back of the engine. So the driveshaft appears to be ok. Thinking it may the bevel gear that Mr Zooks repaired on his. http://members.dslextreme.com/users/...pair_zooks.pdf

Can I get at it without pulling the engine? Or is there something else I can try to rule anything else out?

[PaGS850]

Pulled the boot back off where the shaft goes into the engine, started loosening the bolts, and a #7 sheared bolt dropped out. Don't have it off yet, taking a break in this heat, but it looks promising. Thinking I can get away with pulling the swingarm instead of the engine.

[Steve]

Pulling the swingarm is sufficient. I changed out both sides of the bevel gears in an 850 without pulling the engine.

It's tight, but it works.

.

[PaGS850]

Pulling the swingarm is sufficient. I changed out both sides of the bevel gears in an 850 without pulling the engine.

It's tight, but it works.

.

Finally! a good answer! Really didn't want to pull it. got all 4 bolts broke, just waiting for it to cool a bit. It broke close to the head, so I may be able to get it out once I get the shaft off
Got all 4 bolts into the engine off. One was bent. Wondering if I need to disconnect the final drive, or just drop the swingarm now

[PaGS850]

We have a winner!

Ok.... got it... when I dropped the swingarm, there was a sheared bolt to the niversal. ONE. No other bolts in the boot, had to be like that from the factory and held for 32 years. Just went and got four and putting her back together. Pictures later...