frozen shifter

[Guest]

When I bought the bike, it was a non-runner but would allow you to put the bike in gear and then pop it into neutral. I did remove the clutch cover for cosmetic clean up and replaced the clutch cable. OK... when I now get the bike started, it runs fine but the shifter won't move. Took off the cover over the shifter to ensure it wasn't binding somehow (on left side) and shifter won't move. Could I have done something under the clutch cover that is not allowing the shifter to move? I didn't mess with the clutch hub, etc. Any tips would be appreciated. I hate to toss 3000 ml of good oil but that will likely be the next step.

[dorkburger]

Not sure, but the cover bolts are different lengths and need to be in the corect spot. A long bolt in the wrong spot can hit the clutch basket. Regarding the oil- on my bike (1150) is on its side stand, I pace an inch or so thick block carefully under the side stand and I can remove the clutch cover and lose no oil.

[geol]

I measured the bolts when I took them out and put them in a cardboard mockup and when I put the cover on, thought i had used the same length bolts. I don't understand how putting the block under the sidestand will help. Perhaps putting in right on the side stand so it sits down at the other side of the bike from the clutch cover will work? In any case, I am going to give that a shot or I may drain a quart and then try that and then I will start removing the bolts one by one and see if that is the problem. Thanks... it is a start. If it doesn't fix the problem, then I will have to knock the cover off anyway and look inside.

[fastbysuzuki]

Did you get the rack and pinion lined up correctly when you put the case back if not the clutch will not work and you will need to drain the oil remove the case and line them up correctly see 23 &27 in this link.

http://www.cmsnl.com/suzuki-gs1000g-1980-t-usa-e03_model15990/partslist/BLCK0006.html#results

First put the bike on centre stand with the engine stopped try to move the rear wheel and see if you can select a gear or two whilst doing so the chances are you will be able to find a gear (you can do this without operating the clutch lever) if so then revert to the first part of this post.

[tkent02]

The clutch has nothing to do with not being able to move the shift lever. Completely separate mechanisms. You may have gotten the shifter mechanism behind the clutch in the wrong position, now it's binding. Take the cover off again and see. And you don't need to drain the oil, just put the bike on the sidestand.

[geol]

Thanks for the tips guys... none were exactly what the problem turned out to be. The best tip was to set the bike on side stand. Just put some rags under the cover and pulled it off. As far as the clutch cover bolts, they were all correct length and in correct position and I actually don't think a bolt could actually be too long as they are all in blind holes around the edge on the GS1000 cases. The clutch indeed has nothing to do with the shift mechanism and tkent02 was exactly right. There is a sort of ratcheting shift pawl mechanism that has a return spring so when you push down on the shifter and it turns the shift drum or whatever passes on one of these machines (not exactly a drum but a cogged type affair, the spring returns the shifter upwards.

In any case, I had removed all the engine covers including the shift shaft cover for clean up. The first cover I put on (since it doesn't have a gasket) was the shift shaft cover. While installing it over that little bushing in the cover I had shoved the shift shaft to the right side of the bike a bit while trying to put the shift lever back on. OOOOPS.

This pushes the shift shaft over and on the other side of the engine behind the clutch, the pawls and spring came off their location around that stud type thing. I never noticed. This means the shifter didn't move since the pawls were sort of wedged under that stud thing.

Cover came off and I immediately saw the problem. Located the pawls / spring correctly and am now in business. When I get done drinking my diet 7UP (it is warm out there today), I am going to try it for a test ride. For fastbysuzuki.... on this bike and I suspect all of them with this type clutch actuation (rack/pinion), you can't put the cover back on without them meshing with the cover being seated so I don't think you can screw up the meshing of the rack and pinion if the cover sits flush against the engine cases. I do thank you for the suggestion. I have only had a couple Suzukis in the past; an 82 GS1100E and a 2001 GSF1200F (Bandit) and I owned the first back in the early 80s and don't remember much about working on it and never really messed around mechanically with the Bandit so this process has been a learning experience.

It is probably best you screw up everything you do on a bike when you do it the first time unless you can read instructions (I can not) as it helps you remember how things go correctly after redoing them a second time.

Again thanks!