The bike stays in drive when i pull the clutch in. 1981 1000G

[Guest]

Rebuilding a 1981 GS1000G.
I have the engine back in the frame and connected to the drive shaft.
When i run through the gears, everythink clicks in just fine.....BUT
When i pull the clutch in, it does not disengage the drive.

There is no oil in the engine yet, as i have to fit a new gasket on the clutch side anyway, not sure if that's relevant or not.

Would this be normal?
I did not see anything awry when i checked inside the clutch cover.

[Rich82GS750TZ]

I'm no expert but I'm thinking that attempting to operate a wet clutch dry might be giving you the issue you're having and may damage the clutch. Or I could just be all wet.

[gsrick]

You should soak the friction plates in oil before installing them. That may or may not be the problem though. Check a parts fiche to make sure you have all the parts and that they are in the correct order. When you pull the lever back, do you feel the tension of the diaphragm springs? How much free play do you have in the lever? The gap before you feel engagement should be somewhere between 5-10 mm.

[Steve]

Just to make sure I'm understanding this correctly:
- you don't have oil in the engine because you need a clutch gasket. That is not a problem for this operation. However, ... you DO need to have the clutch cover installed to be able to check clutch operation. The missing thickness of a gasket will affect the cable adjustment, but will at least let you know that it works.

What exactly happens when you pull the clutch lever? If it operates smoothly, but with virtually no resistance, you likely need to preset the release mechanism at the clutch cover. Start at the top, adjust the clutch cable for maximum slack. Move to the bottom, where the cable screws into the bracket on the engine case. Remove the screw from the clutch arm, pull the arm off the shaft. Rotate the shaft counter-clockwise as far as it will go, put the arm back on, tighten the screw. Adjust the cable at the lower mount until there is very little slack, then move to the lever on the handlebar to fine-tune the slack. You should have proper operation now.

.

[gdayjr]

This was a running bike before the restoration.
There is no oil in the engine due to the sump being removed for a good clean up and inspection of the gunk in it.
The clutch cover is in place, as is a gasket.
The lever has all of the feel you would expect, and the lever on the top of the housing moves as expected, but the drive does not disengage, i am hoping it will come good when i fill the engine with oil.
All gears work as expected including neutral.

[tom203]

"I did not see anything awry when i checked inside the clutch cover."

If you had clutch cover off, chances are good that clutch arm pivot fell out of position during cover reinstall. Very little slack needed here or clutch hand lever won't have enough throw

[gdayjr]

I am sure it is nothing to do with the clutch lever or the connection to the pivot lever, both have the correct tension, and plenty of movement at the lever end.
I have changed nothing on the clutch during the re build.
I am hoping that it is just down to the lack of oil in the engine.

[tom203]

Well , I'm convinced- I think! Put the new clutch cover gasket on, and add oil!

[Steve]

Oil in the crankcase isn't going to do anything to enhance the release.

If it still sticks, leave the bike on the centerstand, put the transmission in gear (3rd, or higher).
Spin the engine to get the rear wheel rolling, then pull the clutch lever and step on the rear brake.

Make sure nothing is in front of the bike.

.

[gdayjr]

ERRR, and that does what exactly?

[tom203]

ERRR, and that does what exactly?

Keep you from launching!

[Brendan W]

ERRR, and that does what exactly?

The mechanical equivalent of giving the clutch a slap on the head and telling it to get out of bed.
Sometimes the fixes seem a little agricultural but it's a time honoured way to separate clutch plates.

[2BRacing]

If the clutch plates are "stuck" together, you can also free them by selecting 3rd or higher gear (engine not running), sit on the bike with both wheels on the ground, and "rock" it back and forth.

[gdayjr]

OK, makes sense now.
I am putting the new gasket on tomorrow, so i think i will take all of the plates out and give them a clean up.
I am thinking it is something minor, but i have not come across this situation before.
The engine has been without oilr about three months now.
This is my first major rebuild, so its all about learning.

[850 Combat]

My guess is post #6. If you didn't deliberately make that right with the clutch cover off, it probably isn't right.