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Some background first: I picked up this 1100G project from someone else. Basically, an 82 1100G with 39K miles, complete and an 82 1100GL rolling chassis with an engine with only 6,900 miles. The idea was to just transfer the lower mileage engine from the L into the complete G bike. Why? .. I was told the PO wanted a lower mileage engine in his G.
The project looked to be going in the right direction when I got it. The engine had fresh oil that you could see through when looking through the oil level indicator. All the gear oil was as clear as could be. The carbs had been cleaned and rebuilt... even the float heights were correct when I measured them. It looked as if everything was being done right when I got this project.
I have since swapped the engines, replaced the rear wheel spline as the original was shot. Adjusted the valves as they were off. I figured at 6,900 miles it would be due a check since the manual says to check at 7,500 miles. They were all tight so I'm guessing they were never done since this bike was bought new.
My problem is this. When I finally got all the electrics fixed and could read the instrument gear indicator, the bike would start at neutral, go up to second, third and fourth gear but not go into fifth gear. Going back down, I would go from fourth to third to second to neutral but not be able to go into first. I began trying to adjust the clutch cable but don't seem to be able to get it right. Now, after all my attempts, it just stays in neutral and won't shift up or down. I know it was going through several of the gears in the beginning but not now. So I'm thinking my issue is in the clutch cable adjustments. I also know that a bike sitting for a while can leave the clutch plates a little sticky and running it might loosen them up but I don't see where adjusting the clutch cable would make things worse. I'm at a loss.
Below are a few pics showing the clutch cable and how it sits before and after I pull in the clutch lever. The first pic shows where the clutch cable arm sits when I pull in the clutch lever. The second pic shows how the clutch cable arm as it rests without pulling the clutch lever. Is this how far it should travel? Any ideas?
The project looked to be going in the right direction when I got it. The engine had fresh oil that you could see through when looking through the oil level indicator. All the gear oil was as clear as could be. The carbs had been cleaned and rebuilt... even the float heights were correct when I measured them. It looked as if everything was being done right when I got this project.
I have since swapped the engines, replaced the rear wheel spline as the original was shot. Adjusted the valves as they were off. I figured at 6,900 miles it would be due a check since the manual says to check at 7,500 miles. They were all tight so I'm guessing they were never done since this bike was bought new.
My problem is this. When I finally got all the electrics fixed and could read the instrument gear indicator, the bike would start at neutral, go up to second, third and fourth gear but not go into fifth gear. Going back down, I would go from fourth to third to second to neutral but not be able to go into first. I began trying to adjust the clutch cable but don't seem to be able to get it right. Now, after all my attempts, it just stays in neutral and won't shift up or down. I know it was going through several of the gears in the beginning but not now. So I'm thinking my issue is in the clutch cable adjustments. I also know that a bike sitting for a while can leave the clutch plates a little sticky and running it might loosen them up but I don't see where adjusting the clutch cable would make things worse. I'm at a loss.
Below are a few pics showing the clutch cable and how it sits before and after I pull in the clutch lever. The first pic shows where the clutch cable arm sits when I pull in the clutch lever. The second pic shows how the clutch cable arm as it rests without pulling the clutch lever. Is this how far it should travel? Any ideas?
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