Shifter binds up after clutch cover installation

[Guest]

I put new clutch springs in my brother gs850L after tightening the cover with a 3/8" ratchet the actual foot shifter lost its spring. I took it back off to make sure I got the cover to engage correctly with the clutch arm in the basket. I then put it back on and tightened it down and same thing. I loosened the bolts and tightened them in a star sequence and it seemed to help but still not as loose as my 1000g or dads 850L. Does anyone have a clue what causes this, it's like tightening it binds the clutch basket actuator thus causing the shifter to be super tight

[tkent02]

Take the clutch cover off and look closely at the shifter mechanism. There are a few things it could be, all easy to do with the cover off.

[bwringer]

I've encountered this with aftermarket gaskets that are too thin. There's a nubbin on the inside of the cover that keeps the shifter shaft from sliding too far to the right.

If you install the cover with a cheesy thin gasket, this nubbin will contact the shifter shaft and cause binding.

If you're determined to use a thin gasket (maybe zombies will eat your brains if you don't get the bike moving), you could likely get away with shaving a bit of aluminum off the nubbin. Me, I'd just order up the correct gasket.

Not sure how thick the OEM gasket is, to be honest. But it's pretty thick, stiff stuff. Maybe .7 to 1 mm. Definitely not just paper.

[Gs1000g]

Thanks guys, I took the cover off and cleaned it the clutch assemble all is new and worked before I put in the springs, the gasket seems to be super thin so I'm assuming aftermarket gasket is bottoming out, that would explain while slightly loosening bolts it frees itself up. I will order an oem gasket and report back

[tkent02]

You should be able to see if that little nubbin has been touching. Sounds like the culprit though.

[geol]

What is a nubbin? I had the cover off my last GS1000; first to clean/clear coat my cover and then to install the shift shaft pawls back where they went. I don't remember anything about the shift shaft or pawls being near anything that might contact it if a gasket were thin. Please explain.

[bwringer]

http://www.dictionary.com/browse/nubbin?s=t

On the inside of the GS850 clutch cover (I have no idea whether the GS1000G has the same thing) there's a small round projection on the inside of the cover that's in line with the shifter shaft. This projection is intended to keep the shaft in place, so there's supposed to be a little bit of clearance. If the gasket is too thin, this projection can make hard contact with the shifter shaft on some bikes and can cause it to bind.

Many aftermarket clutch cover gaskets are far too thin -- gaskets cut from the incorrect material are all over fleaBay. The ones I've seen are paper thin -- about the thickness of a grocery bag. The correct gaskets are pretty heavy -- much thicker than cereal box cardboard, for example.

All that said, the thin gaskets usually will seal OK, but if they bind the shifter shaft you'll have to trim some aluminum off the "nubbin" or source the correct OEM gasket.

[blowerbike]

my experience with the shaft drive big GS's is they have a support extension on the shift shaft that rides in the clutch cover.
if you try to silicone instead of using a gasket the shift shaft will bind because of lack of clearance in the clutch cover from side to side.
a thinner gasket would result in the same type of binding.

[geol]

Thanks for the explanation, I had the clutch cover off my 80 GS1000GL a couple times and didn't notice the extension of the shift shaft but I just had the cover off my 80 GS1000G to clean the cover up and saw exactly what you refer to... thanks for the patience. I had trouble with the sifter because I put the shifter engine cover on first after cleaning the cover and pushed the shift shaft in far enough to knock the shift pawls and return spring off the place where they sit. I put the clutch cover on and didn't notice and bingo, the shifter was stuck. Didn't do it this time because I am smart enough to not screw up the same thing more than 3 times before I learn.