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1982 GS650G Clutch Case Removal

  • Thread starter Thread starter jgoheen
  • Start date Start date
J

jgoheen

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I have a 1982 GS560G that I am trying to replace the clutch on. I have taken all of the bolts out of the case to get to the clutch and the gasket is free. My problem is the spline on the clutch. It seems like this is what is holding the case on. Is there a trick to getting this case off or unlocking that shaft from the clutch basket? Any help would be greatly appreciated.
 
Put the arm back on the spline & move while pulling the case off...
 
Not really sure, is the cover at least loose?

Watch the spline to see which way it moves when you try to pull the cover off - tighten the lever to the spline and whack it with a rubber mallet...

Mine did the same thing as yours when I tried to remove the cover to rebuild the clutch. Turns out a hunk of red silicone (no doubt a leftover from its "liberal? use on the valve cover) had gotten stuck in the spline. A little persuasion & off she came.

That spline has to rotate in order for the cover to come off.
 
The case is not loose. All of the bolts are out, but there seems to be the tension and I was not able to get the spline to move one way or another last night. I will give a shot again today. With a rubber mallet i can tap the cover and it will move from side to side slightly but just will not come off. I might just need to pull on that spline a little harder.
 
This might seem like a silly question, but you do have the cable disconnected from clutch actuator arm?
 
It will be interesting to see why the spline isn't cooperating, once the cover is off.

good luck
 
So, just to summarize:

1. You have all of the bolts off
2. The clutch actuator arm is off the spline
3. the spline will not rotate (does it move with the use of the clutch lever, when attached?)
4. you've whacked the case on all sides and it is moving around, but doesn't move out?

Are you sure the gasket is free? You can still get some wiggle if part of it sticking to both sides. Those gaskets have a surprising amount of strength. The case will wiggle, but then you have to get some really good purchase to pull it off.

While you are at it, run down to your local auto parts supplier and get yourself some Permatex gasket remover. (btw, that stuff makes for an awesome powdercoat remover if it can get under the coating...be careful with it's application)
 
Well I got the cover off. Is the spline supposed to move freely? To get this one to move I had to hit the clutch perch with a mallet to get it to move counter clockwise and get the cover off. Seems like that spline should move freely when they is no tension on it. I found a used one on eBay, but before I pull the trigger I wanted to know what you guys thought.
 
Every other cover I have ever taken off that had a spline like this always turned really easily. I cannot move this thing by hand even with the cover off. Looks like I might need to find a new cover.
 
You don't need a cover. If you remove the arm and pop the shaft out (down) there is a replaceable bearing and oil seal. Just order those from the dealer and replace them. Around $15 plus shipping.
 
Ok that works. I will let you guys know how it goes getting the shaft out.
 
jgoheen said:
Ok that works. I will let you guys know how it goes getting the shaft out.
Click to expand...

Glad to see you got the cover off :).

Yes, I removed my spline shaft from the cover as well to clean it out thoroughly... didn't replace any of the components (as I remember) but did notice a small crack in the part where the shaft gets pressed into - decided it wasn't going to do any harm so I left it as is & haven't had any issues.

You have to drive that shaft out using a drift pin & a hammer - the bearing & seal should come out the top with the shaft.
 
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So it looks like it gets pressed from the bottom to the top correct? I got home from work late tonight so I did not get to work any, but tomorrow is another day.
 
Well I found the culprit. New bearing and oil seal are on their way. The bearing was cracked in 3 places and completely rusted to the point where none of the roller bearings would even turn turn. Gonna clean the rust off that shaft where the bearings seat and wait on some parts.

10337734_686522464727229_1232187708699977287_n.jpg
 
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