Help! Shifting issues after changing clutch springs

[Guest]

Hello all,

So I am the proud owner of a 1982 GS850. I was experiencing clutch slipping issues around 6-7k on gear shifts. I just changed the clutch springs, and the clutch cable (mine was beat up and fraying.)

The clutch slipping isn't an issue anymore the springs fixed that, but now I cannot get out of 3rd gear. 1st is good, neutral is hard to get into and 2nd is tough as well. Once I'm in 2nd the shifter doesn't bounce back down to neutral position in order to get to 3rd 4th and 5th.

Does anyone one know what I did wrong? Bike shifted perfectly before I did any work.

Thanks
Brian

[tkent02]

Probably knocked the shift shaft from the left side which can dislodge the pawl from the little pins on the shift drum. It's easy to do with the clutch cover off. Also check the shifter return return spring didn't get on the wrong side of the pin that it rides on.

[geol]

Sure. The shift rod goes through the engine cases and comes out just behind the clutch hub; down and to the left. When you mucked with the clutch, you pushed the shift rod towards the left hand side of the bike and the shift pawls are no longer engaging the part that comes out from inside the engine that they grab. Take off your clutch cover (again) and take a look. I did the same thing when I cleaned up my case covers on my last GS1000. You may want to drain a bit of oil; can't recall if there is oil loss when you pull this cover as I drained all the oil before doing any of the covers.

[tkent02]

Not required to drain the oil, just put it on the side stand. A little will drip from the cover but not much.

[Brianburkhardtjr]

Thanks guys, I took everything apart again, but nothing seemed like it was out of place, the spring looked like it was in the right place. I installed the cover back on and sat on it and went through the gears, they went through 1-5 no issues, I did have to roll the wheel back and fourth to get in and out of some gears but nothing out of the ordinary. Maybe im just not used to a the new springs being so tight? I'm sure the springs are right, I bought them from the dealership.

I will test ride tomorrow night when I get off shift and let you guys know. It's much too loud to start up at midnight.

[Brianburkhardtjr]

Just wanted to also confirm that you do NOT need to drain any oil for the gs850 to remove the clutch cover, just leave it on the side stand and you won't lose anything. A few dribbles come out from the cover being removed but nothing a rag can't handle.

[tkent02]

The shifting has nothing to do with the clutch springs, a lot of us never use the clutch to shift. Let us know how it works.

Did they sell you some aftermarket heavy duty springs, or the original Suzuki ones?

[Brianburkhardtjr]

Original springs

[tkent02]

Good .

[Brianburkhardtjr]

Everything is working 100% thanks for all the help guys

[sbmisajw]

Hey guys,
Several of you have mentioned that there is no need to drain the oil prior to removing the clutch side case on the GS 850 motor.
I am just wondering if it is necessary to drain the oil on my 82 GS1100L before I remove the clutch side case? Reason I ask is because I just replaced my really trashed entire clutch basket with a very nice one I purchased on ebay, inner and outer because the damage from PO's. At the same time, I also installed new friction plates and springs from EMC, cleaned up the metal plates, installed a new cable from Motion Pro (my bad?) and now I can even get the clutch lever to move at all. It's like it's frozen. I've drained the oil,to remove the clutch cover, at least 3 times now trying to figure out what I did wrong. (I'm not putting the oil back in now until I get it figured out. lol)
Everything seems to move smoothly until I tighten the case bolts to 8.5-10 foot pounds pounds. I tighted them in a star type pattern a little at a time. I even disconnected the cable from the release arm and tried to move the clutch release pinion with some slight pressure on a crescent wrench. That didn't work either can't even move it a little.
What did I do wrong besides draining and refilling the oil 3 times. lol How critical is it to remove all those grooves in the hubs?
Thanks in advance!

[tkent02]

Just a guess, you used an aftermarket clutch cover gasket?

[sbmisajw]

Hey tkent02
Yes I did use an eBay special gasket for the clutch cover. I'll buy an OEM from my local dealer and give it a try. Dang, it's hard to believe that the gasket thickness could make that much difference!
sbmisajw