GS850 clutch problems

[Guest]

I have a gs850l put in new clutch and clutch cable , when I start it on the center stand and put it in 1st gear it grinds and the tire starts spinning. When you put pressure on the tire while spinning it stalls , to eliminate the cable I worked the clutch lever on the engine with pliers and got the same results. I took the clutch a part and checked everything put it back together same problem any Ideas what I should do next ?

[bwringer]

What, exactly, do you mean by "new clutch"?

I suspect you installed new aftermarket clutch springs. These are far too strong and will cause the clutch to drag badly. Order up six new genuine OEM clutch springs from Suzuki -- see your friendly neighborhood Suzuki dealer or visit one of the many websites that sell Suzuki parts. Remove the aftermarket springs, toss them into nearest metal recycling bin, replace with the OEM springs, and enjoy.

Of course, it's also possible you assembled things incorrectly. With the engine off, remove the oil filler and see if it looks like the clutch is moving a little and relieving pressure when you pull the lever.

I've also seen crappy aftermarket clutch kits (like the "extra plate" kits from Barnett) cause a lot of drag. The EBC kits are usually OK. Unless there's been horrific abuse, a GS850 clutch should pretty much outlast everything else on the bike.

[Who Dat?]

You put in "new clutch and clutch cable". I understand the 'cable' part, what are you calling "new clutch"?

[ceh3523]

I installed new KG clutch plates and springs .

[Who Dat?]

The plates are probably OK, but as bwringer said, pitch the springs, get some genuine Suzuki springs.

[ceh3523]

OK I put new OEM clutch springs in and I still have the same problem, what do I do next ?

[TxGSrider]

Did you replace the friction and the metal plates?

[ceh3523]

Yes all new plates, when I put the new springs in I hand tightened bolts until they bottomed out then torqued to 8 ft. lbs. is this correct ?

[Dogma]

I don't remember if 8 ft·lb is correct, but that is the correct procedure. Was there any damage in the basket where the plates engage, or dragging before replacing the plates?

[ceh3523]

There was some wear on the basket but I cleaned up with a file. Looking thru the oil fill hole I can see the plates moving maybe 1/16th of an inch , how much movement should there be ?

[TxGSrider]

You may want to measure the plates and steels and see if they are in spec. If they are too thick due to manufacturing tolerances that would cause them to drag.

[bwringer]

The amount of movement visible seems normal.

Sitting here without the bike in front of me, it's very hard to tell what's wrong. A few thoughts...

1) You could just have a case of slightly "sticky" new plates combined with thick, cold oil. Perhaps your "sneaker stop" test just isn't quite enough force to break the plates loose against slightly higher than normal drag. In other words, it's somewhat possible you just need a little more force to break the stickiness. With the bike on the centerstand, you can try using a little more throttle and the rear brake to get things moving. If you still stall the engine, well, then it's time to delve deeper.

2) You could have aftermarket plates that are slightly thicker than they should be. It doesn't take much -- the tolerances are pretty small.

Related side rant: After being screwed over time and time again, I've really lost almost all trust in aftermarket components, and I've noticed a distinct decline in formerly reputable brands. I have no idea whether KG's components in particular are any good or not. I've installed Vesrah and EBC fiber plates in years past with no problems, but I have no idea whether their current clutch products are any good at all.

3) Probably a dumb question, but are you 110% sure the total number of steel and fiber plates is exactly the same as what came out? Some clutch kits come with extra plates so they can cover more applications, but you're supposed to leave the extras out.

[ceh3523]

No such thing as a dumb question and yes I am sure there was no extra plates , I was wondering about the sticky plate thing I'll try your test tomorrow. If it still doesn't work then I'll take it apart again and measure the plate thickness again to make sure .

[hillsy]

Did you soak the friction plates in oil before you installed them?