clutch with no friction zone

[dfinnegan71]

I remember the instructor of my riders ed course calling the feeling of the clutch grabbing "The Friction Zone" Well, here is the issue. I just recently got my project 1980 GS 550L up and running and I when I first put it into gear, goes in no problem, but there is literally no friction zone. The clutch goes from totally disengaged to completely engaged while I am easing the clutch lever out. It's like BAM! your moving forward. Of course, not a problem once moving. Do you guys think this will work itself out over time? It sat since 1995. Or do I need to replace clutch springs? Plates? I'm clueless on this one.

[almarconi]

Did you try adjusting the cable?

[dfinnegan71]

Yup. I forgot to mention that. I have adjusted it up down back and forth. That's why the confusion.

[almarconi]

If the clutch springs are original they should be replaced. The service manual probably has a service limit for the length. They are cheap so I would just replace them anyway.

[bellucci]

I just had a look at an old clutch basket today and they get grooved which makes them grabby... don't know if you looked at the basket without the plates removed... just another idea.
Curt

[bellucci]

Another thought. Are the fibers new? Has it been sitting a while? Sometimes the clutch pack sticks together. If they were new, usually soaking them in fresh oil before installing helps a gradual engagement.
OK I'm done...
Curt

[blowerbike]

did you adjust the worm gear?

[dfinnegan71]

Thanks guys. To answer some questions:
1. No I didn't adjust the worm gear
2. It has been sitting a VERY long time. 17 years I think
3. I didn't even look at the basket yet, but i assume nothing new in there.

Thanks again for all your advice.

[Colin Green]

As you let the lever out, is it pushing against your fingers (can you feel the spring pressure) evenly through the release? Just wondering if for some reason the springs are binding a bit (not 'springing back straight away').

Only thing I can think of from reading your description is stuffed or sticking springs. I don't think it would be a friction plate issue. Though maybe if its been pulled down and put back together with a doodah around the wrong way?? Hopefully someone who has experienced the same issue will pop in and tell you what's what. Starting to lean toward the delinquent doodah scenario the more I think of it.

Just to clarify, have you tried a really slow clutch release (say over 10 seconds from fully in to fully out)? If so, at what point of lever travel does the 'friction' kick in? and (without any further release of the lever), is the 'friction' at full or does it require a little bit more lever release before it is at full friction?

[dfinnegan71]

The lever does push against my fingers. I actually feels very similar to every other old bike I've ridden. I didn't do a 10 second release but probably a real 5 second release. It grabs very abruptly at almost all the way out on the lever. And it is at full engagement.

[cableguy]

I think your cable needs some slack taken out of it so it grabs much sooner. That adjustment is down on the trans. Then you can play around with the lever adjustment to fine tune it.

[blowerbike]

did you adjust the worm gear?

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[dfinnegan71]

No adjustment to the worm gear. Where is it located? I don't know anything about it...do tell.

[blowerbike]

there is a cover on the sprocket cover.
remove cover and you will have a screw and jam nut.
loosin jam nut and run the screw in until it lightly touches then back out one turn and jam the nut back down without causing the screw to turn.
make all other adjustments on the handlebars.


aka WORM GEAR

[Thumper88]

I've got the same issue with my GS450, and the worm gear is properly adjusted.
I had the clutch cover off before, the fibers didn't look very good to me but I was wanting to ride after doing so much work to it.
I did put new EBC clutch springs in.

I have some new fibers, just need to install them. I do have a friction zone, but it's really small....