1980 GS550 very hard to shift

[linge]

Hey so I bought a 1980 GS550L a few month ago, it has ~20k miles on it. Recently I changed front brake and clutch levers, because the old ones were battered. Also I have removed the clutch cover and front sprocket covers to check the condition on both (had to take off the shifting lever and foot peg to do so). After these changes I am experiencing some problems with shifting. When the engine is off, I can shift easily and experience no problems. However, when the engine is running its almost impossible to shift by foot (I have tried it with my hand and its possible, but very hard as well). I suppose this problem is not caused by the clutch itself, because when I do shift into 1st or 2nd gear while the clutch lever is engaged, the bike is not trying to move. The engine oil was changed quite recently and level is good (does the clutch and engine share the same oil though?).

After doing some research I figured that it might be false clutch cable adjustment or gear shifter is in wrong position by few teeth (still didn't check on these). Any other ideas or suggestions?
Please note that this is my first bike, so any comments or suggestions are welcome. Also, any advice on how to adjust the clutch cable or gear shifter correctly?

[cowboyup3371]

Yes, the oil is used for both the engine and transmission. What oil did you use - a motorcycle specific, diesel (preferred here by some due to cost and the zinc content) or hopefully not car oil? Did you follow the procedure in the service manual that you can find here at Basscliff's site (http://members.dslextreme.com/users/bikecliff) to adjust the clutch lever after reconnecting the cable? When was the last time the cable was replaced?

[linge]

Thanks for the reply. The oil was changed using the manual, using specified oil, so im sure its ok. Im not sure when the cable was changed, but it had only one owner in the Netherlands, and it has only 20k miles on it so i guess it wasnt changed since it rolled out of factory. But i thing its still in decent condition, as while inspecting it, couldnt see any wear or tear signs. Do you think I should try to play with the gear shifter after adjusting the cable? Could it be causing problems?

[allojohn]

Sometimes the sprocket cover binds with the shift lever if it's not absolutely straight when tightening. Loosen it up, see if that fixes it.

[bwringer]

What gasket did you use for the clutch cover?

If you use a crappy aftermarket gasket that's thinner than stock, you can have problems like this if it binds the shifter shaft.

The stock Suzuki gaskets (and some aftermarket gaskets) are fairly thick, 1mm or more.

[linge]

Also, when on the kickstand, engine on, I can shift up and down no problem, but when I put gear in, rear wheel starts to turn (with the clutch engaged). Up-shifting is easy with these conditions. But if I try same process with both wheels on the ground, up-shifting is really hard (even though the bike doesn't move in gear and clutch engaged). Does this indicate that there's something wrong with the clutch cable?

[Steve]

Likely an adjustment issue.

Your problem is that there are THREE adjustments that need to happen.

Start at the top, loosen the locknut at the clutch lever and turn the adjuster IN to maximize the slack in the cable.

Now remove the cover that is just inside your left boot. I believe the shifter lever and the footpeg have to be removed. There is an adjustment where the cable attaches to the crankcase. Ensure there is plenty of slack there.

1. Adjust the helix that is pulled by the clutch cable so there is just a little bit of play, then lock it in place.

2. Adjust the cable at the engine so there is just a little bit of play, lock it in place.

3. Adjust the cable at the handlebar so there is just a little bit of play, lock it in place.

.

[Mr.humbucker]

IMG_0945.JPGNot sure this is the problem but I know that from my experience when I was reassembling my GS550T I didn't grease this gizmo, in particular the nylon housing which made compressing the clutch lever near impossible.

[linge]

Thats for help everyone. I made some adjustments on the clutch itself and the cables and now its much better. Its not perfect but at least usable for now.