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GS1100 Clutch Problem!! HELP

  • Thread starter Thread starter ghainjr1
  • Start date Start date
G

ghainjr1

Guest
81 GS1100E Not going in to Neutral very well and occasionally hearing what sounds like some kind of spinning noise. I'm trying to put in some pics,dont know if this is going to work or not.Can anyone tell me what happened. Whatever happened I must have done when I changed the clutch. Everything is new. I have more pics but this seems to be all I can post.
 
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That photo doesn't show much. It does look like something let go at one time.
 
Something must have but I dont know what. How can I post more than 1 pic?
 
1 Pic per post:-( Did you change just the friction plates, or the entire clutch? Sounds like either the main bolt needs to be tightened or your bearing is bad. Did you tighten your pressure plate bolts to just snug? Looks like you threw the notorious backing plate spring at one time.
 
6-15-06
Today I have put it all back together and grab ahold of the hub sleeve and everything is nice and snug. I grabbed ahold of the primary gear drive and can wiggle it back and forth. I thought maybe just the aluminum housing was moving but I grab the gear itself and the same thing. Anybody think that could be just the bearing, which is very loose fitting, or something else?
 
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ghainjr1 said:
Something must have but I dont know what. How can I post more than 1 pic?
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Ghainjri 1, go to photobucket.com and sign up there.That will let you link your photos for people to look at like I have here.
 
Anybody know where to get some good used or preferably new parts. Tried the Suzuki dealer and most of what I wanted will be backordered for 4-6 weeks.
 
Where is your backing plate that is supposed to be riveted to your driven gear?
 
ghainjr1 said:
Come on guys, pictures! Does anyone have any thoughts on this?
http://s53.photobucket.com/albums/g72/ghainjr1/
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I believe that when you put this back together that you didn't have the oil pump drive gear and the slots in the back of the clutch aligned. Looks like the thrush washer has a little blue color from heat. I have never seen a backing plate like the one you have but it looks like they did a nice job on it. If I were you, I would have the clutch hub checked for balance because of the nick that you have in it. Get some high volume oil pump gears to replace the damaged on that you show in the pictures and make sure that you follow the steps real close when you put it back together for the last time.With everything out of the case there is a washer that goes behind the oil pump drive gear spacer. Then install the oil pump drive gear and bearing with the notches looking towards you. Install the clutch hub without the bearings and line it up with the crank drive gear and here is where you have to make sure that the oil pump gear and the clutch hub lines up correctly. With that being done you install the clutch hub bearings and spacer with the oil groove facing inside. Install the clutch hub sleeve, lock nut washer and nut. Tighten and check to make sure that the inner hub spins freely and there is not too much play in the outer hub. Install the rest of the clutch plates and the pressure plate and springs and you should be good to go.
 
Lots of worn parts. The gear with the dogs (primary drive) doesn't look good. The spacer is bad and who knows what else. The backside of your clutch basket looks wierd. Are springs behind those covers, or did someone eliminate the springs with bits of tube?

Looks bad to me.
 
Good to see you back Jeff. JGORDON is the man to listen to. He is a master of these machines.
 
I would agree with all the recent comments about the clutch basket, i've never seem one like that before.

I'd change the oil pump drive cog (one with the the two lugs) and get one of the small 'cushions' that fit into the hole in the clutch basket where the oil pump fits to.

There should be a washer that goes on the main gearbox bearing, then the oil pump drive, then the clutch basket, bearing, spacer. The washer with the slot should go next, slot facing in towards the clutch basket. Then the inner basket, tab washer and nut! fit the plates and other bits job done.

If you start replacing parts such as the pump drive or the main basket check for play as later bikes had a small shim to give a set tolerance that was not present on the early models like yours.

Suzuki mad
GS1000E 1981
GSX1100ESD 1983 Fully functional (Boy it's quick!)
 
It appears to me like the clutch basket threw a spring out of the back of it. The spring damaged the pawl holder, the pawls and the pawl lifter piece. This will cause shifting problems. In any given gear, the pawls should be an equal distance from the center of the pawl holder. They appear to be off. Replace these parts for sure. Looks like the PO had the springs covered over to prevent a re-occurence. The damage to the outer edge of the basket should not cause any problem. After installing the center hub and before installing the clutch plates, push in and pull out on the basket to make sure it has some end play in it. This is a good way to determine if the parts are assembled correctly. You could at this time, crank the motor (with the plug wires off) to see if the basket runs true, as it may have been hammered when the spring came out the back. If the pawl assembly is the same as a GS 1000, I probably have a spare or two...........BadBillyB
 
This is the first time I've had everything out. I dont know if this is new or old damage. As for the springs, they are covered by what looks like a piece of tubing cut in half the long way and welded. Pawls are very chewed up along with the gear. I put it back together yesterday and rode it for awhile. It did just fine for about an hour then it started to make its noise again. The clutch felt good, like it did before I replaced it. I"m not sure how I didn't get it lined up right the first time but I did this time. Thanks for everyones help, I really appreciate it. Now its time to order parts and wait 4-6 weeks to get them.
Thanks again, Greg
 
ghainjr1 said:
This is the first time I've had everything out. I dont know if this is new or old damage. As for the springs, they are covered by what looks like a piece of tubing cut in half the long way and welded. Pawls are very chewed up along with the gear. I put it back together yesterday and rode it for awhile. It did just fine for about an hour then it started to make its noise again. The clutch felt good, like it did before I replaced it. I"m not sure how I didn't get it lined up right the first time but I did this time. Thanks for everyones help, I really appreciate it. Now its time to order parts and wait 4-6 weeks to get them.
Thanks again, Greg
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It's not cut in stone that you didn't get it lined up correctly the first time. You've got a bunch of worn parts that need replacement.

If the clutch spring fell out before, chances are that this bike's clutch was taking a beating. If the springs are good, there is no reason for a cover. In fact, it adds a bit of weight that you may not want (it likely unbalances the basket also).

I see that the basket has been welded also.

If it was me, I'd replace all the worn parts, order any that are missing (haven't seen your stack up), and either have new springs put in the basket, or get another and have it reworked. That would depend on the overall condition of it.

A set of 750 oil pump drive gears would be a nice addition.
 
The basket being welded looks like it was bought this way. It looks professional. Paint and all. I dont know what all is in this bike,it was bought this way.
 
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