Before I start clutch work....

[bwringer]

Also, that Wally World motorcycle oil should be good stuff. Super Tech oils, and most store brand oil, for that matter, is made by Warren Distributing, and is well-known to be excellent quality stuff.

[Rich82GS750TZ]

Thanks for that confirmation Brian. I’ve suspected it was ok. But I don’t know anyone else who uses it and haven’t seen any mention if it on the forum.

[Rich82GS750TZ]

Clutch friction plates, all 6 new springs, and new clutch cable have arrived. Plates are soaking in oil. New friction plates do not have notches in the claw ends that I was worried about clocking in a particular way. I want to install the new cable. It's pretty straightforward. But, looking at my manual's cable routing guide, it seems I'm missing the guide that keeps the clutch cable away from the valve cover. There is a slight burn on the original cable in this location so I want to put something there. Maybe bend up a piece of wire hanger. I do have the guide at the bottom and between carbs 1&2 that keeps the cable away from the carbs.

Does anyone know or can measure the thickness of this guide, and how far it should hold the cable away from the valve cover. Wire hanger sound like a good idea? Maybe it's not that important.

Thanks all.

[Rich82GS750TZ]

This might work

[Big T]

I hope you made the big hole large enough for the cable ends to pass thru

And, remember to reset the clutch arm to the correct position

[Rich82GS750TZ]

I did. It’s on the cable. Valve covers is off so can’t completely check the fit but I think it’ll work. Plates are in. Took a dinner/ beer break. Then back to fit the cover.

[Rich82GS750TZ]

Just wanted to post a follow-up to finish out this thread. New OEM Clutch friction plates (I re-used the steels), New OEW Clutch springs, and New OEW Clutch cable, New OEM gasket installed. Everything buttoned up. No surprises. Clutch cable play properly adjusted. The bike did lurch into first with the lever pulled on the first star-up. But the bike had been sitting on the side stand for a few days since I put everything in. So imagine everything was pretty dry, even though I did put the plates in wet.

After that, All shifting was smooth, and no more lurching when kicking it down to first form a stop sign. Took about a half-hour ride and when I brought it back to the garage, found that I could even walk the bike backwards in first with the clutch pulled in. I had a real hard time doing that before. ALL GOOD. Thanks All!

[Rich82GS750TZ]

I have spoken too soon. Was riding for about 1-1/2 hours today. Twice I noticed my throttle seemed to hang. So I pulled out from a stop sign to head home. Went to shift into second, didn’t get it all the way past neutral, I think and the RPMs shot up way past redline, heard an awful rattle from the engine, I hit the run switch to off and pulled into a parking lot. Started the bike, awful rattle ensued. Limped for about 1/2 mile the the bike wouldn’t stay running.

Called a buddy with a trailer. Good thing he wasn’t working, I guess. Got it home and immediately pull the clutch apart. Everything seemed fine there. I thought for sure I screwed up something there. Nope.

So I thought I’d check the throttle. Sure enough, the nifty little piece I made from a wire hanger, that my bike has lived without for 15 years, was pushing the throttle cable too far between carbs 1&2 so that it cases the throttle linkage to hang up.

I am so afraid that I’m going to have to pull the head and inspect. I think I just killed my engine.

I have no idea what to do next. Looking for educated guidance and suggestions.

Before I pulled the clutch cover, when I tried to start it, engine cranked but sounded gutless.

To say my confidence in my mechanic skills is shaken would be an understatement. Should have thought to check proper throttle cable operation before heading out.

FML

[Rob S.]

...way past redline...killed my engine.

So sad. These beasts usually survive trespasses into the red. The only advice I can offer is from a 1978 movie. Remember what Bluto said to Flounder when he returned from the "Road Trip?"

[Rich82GS750TZ]

This one?
And it ain't over now. 'Cause when the goin' gets tough . . . the tough get goin'! Who's with me? Let's go! C'mon!

[Rob S.]

This one?
And it ain't over now. 'Cause when the goin' gets tough . . . the tough get goin'! Who's with me? Let's go! C'mon!

Excellent! I'm a little embarrassed to tell you what I actually had in mind: "Start drinking. Heavily."

But I like yours better. Remember: it wasn't over when the Germans bombed Pearl Harbor.

[Rich82GS750TZ]

Thanks Rob.

As problem go, mine hardly compares to the hell you're going through. At least I can look at my bike. Get well soon, my friend.

I might just do both. Drink Heavily, and get going. I'm just completely gutted at the moment. Will probably start the tear down tomorrow. I've always told myself if I ever have to pull the engine, I might just do a full restoration down to the frame. We'll see. If the engine is too far gone, I may look for another 750 16v engine, or 1100 (I think I've read that it'll fit).

[Rob S.]

...I may look for another 750 16v engine, or 1100 (I think I've read that it'll fit).

IIRC, it's actually quite a common conversion. Search for "7/11" (or seven eleven) and you should find several build threads.

[rphillips]

Dang that's a bummer, & just when things seemed to be going great, but could be a blessing in the long run. Great time to get a good roller bearing crankshaft & rid of the plain bearing crankshaft of the 16V 750. If you can find a pretty good old 16V 1100 eng., "83" if possible, it should be a great upgrade. Plus an eng. change should be way easier than a complete eng tear-down & repair. I've had 2 8V GS1000's & it was a blessing, for both, when I got 16V GS1100 engs. onto them. Hate it for you, but just try to be optimistic. Good luck.

[Redman]

..... . . . . . . . . I think and the RPMs shot up way past redline, . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . Started the bike, awful rattle ensued. ...

I am so afraid that I’m going to have to pull the head and inspect. I think I just killed my engine.
...
. . . . . . . . . . when I tried to start it, engine cranked but sounded gutless.
.
.

Yikes !

THe best thing you can/could do was to post about it here.
ANd let some of the knowledgeable gear heads see it. (I am not referring to myself.)
With their knowledge and your wrenching, a lot of good can happen.

YOur comment about cranking but sounding gutless, makes me think to ask if you have done anything to check compression? Either with a gauge, or the ol' thumb over most of the sparkplug hole trick.