1982 650 stuck in 4th

[Vanzahn]

I recently purchased a Suzuki GS650L and had to replace the timing chain, after doing so the bike has been stuck in fourth gear and won't start. it shifted fine before the replacement but i didn't try to start it due to the fact that the chain was not attached. any help would be very much appreciated.

[tkent02]

I recently purchased a Suzuki GS650L and had to replace the timing chain, after doing so the bike has been stuck in fourth gear and won't start. it shifted fine before the replacement but i didn't try to start it due to the fact that the chain was not attached. any help would be very much appreciated.

Did you split the cases to replace the chain?

[Vanzahn]

no, i tore it down to the case then used a chain break to separate the chain and install it. i also was able to get the engine back together and timed, according to the manual, correctly. it was at this time i tried to do a check of everything and noticed that it was in fourth gear without ever shifting it myself.

[tkent02]

You are turning the rear wheel as you try to shift?

[rapidray]

When you re-installed the case half, you didn't get one of the shift forks in the correct groove. Get ready to take it back apart. Ray.

[tkent02]

He didn't split the case.

[Vanzahn]

yes, i tried to turn the rear wheel while shifting. still no luck, the shift pedal doesn't move at all.

[tkent02]

Did you do anything inside the clutch cover? Part of the shift mechanism is behind the clutch cover.

[Vanzahn]

i did pop that off and then put it back on, but didn't mess with the cogs. i believe i put everything back the way it was. i will take another look though thanks

[rapidray]

Sorry, didn't read close enough as I would have split the cases to change a cam chain since they didn't come with master links. If you removed the mechanism on the end of the shift drum, behind the clutch hub, you didn't re-install it correctly. Ray.

[tkent02]

Also if you set the engine down on the left side, without the shifter in place on the shaft, the shift shaft can be pushed into the engine a half inch or so. When you pull it back out, the shifter return spring won't be in the right place, it pops off it's little pin.
I'm not sure if this can happen on the 650.
Might be something like this happened.

[tom203]

Interesting problem-pull clutch and take a look

[Vanzahn]

thanks for all the advice, i will work with it a little bit more and let you know what happens.