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    Strange Clutch Drag Problem

    On my '81 GS550T I'm experiencing a strange problem I think is related to clutch drag. When the engine is warm there is a fairly loud click/clunk noise when the clutch is released. The noise sounds like the transmission dogs banging together as the lash is taken up. It's very annoying during stop and go traffic, such as when moving up to take my turn at a stop sign. When the bike gets like this the transmission is pretty clunky as well, particularly when downshifting to lower gears at a stop.

    Yesterday I pulled the clutch apart and everything looks like new (bike only has 700 miles on it from new). Running Rotella 5W-40 oil. Clutch performs perfectly as well and adjusting the freeplay has no effect on the noise. Oil level is to full line - not overfilled.

    As an experiment I put the bike on the center stand and ran the bike with the clutch pulled in. Even with the clutch pulled in there is enough clutch drag to spin the tire in relation to engine speed. Each time I rolled the throttle on-off the click/clunk was very apparent.

    I'm really at a loss about this noise - it offends my mechanical sympathy. Any suggestions appreciated.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

    #2
    Loose chain, worn out dog ears or bent shifter forks. Have you ever had to force it into gear and got pretty agressive?
    I think we're pretty close in diagnostics so your guess is as good as mine.:-D
    Could even be rear sprocket cushions.
    1983 GS 1100E w/ 1230 kit, .340 lift Web Cams, Ape heavy duty valve springs, 83 1100 head with 1.5mm oversized SS intake valves, 1150 crank, Vance and Hines 1150 SuperHub, Star Racing high volume oil pump gears, 36mm carebs Dynojet stage 3 jet kit, Posplayr's SSPB, Progressive rear shocks and fork springs, Dyna 2000, Dynatek green coils and Vance & Hines 4-1 exhaust.
    1985 GS1150ES stock with 85 Red E bodywork.

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      #3
      If the engine is oil is cold, the rear wheel will still spin even with the clutch pulled in with.
      Check to see if the front sprocket is loose. It's happend to me and at least two other 550 riders I know of.

      Comment


        #4
        Originally posted by Nessism View Post
        On my '81 GS550T I'm experiencing a strange problem I think is related to clutch drag. When the engine is warm there is a fairly loud click/clunk noise when the clutch is released. The noise sounds like the transmission dogs banging together as the lash is taken up. It's very annoying during stop and go traffic, such as when moving up to take my turn at a stop sign. When the bike gets like this the transmission is pretty clunky as well, particularly when downshifting to lower gears at a stop.

        Yesterday I pulled the clutch apart and everything looks like new (bike only has 700 miles on it from new). Running Rotella 5W-40 oil. Clutch performs perfectly as well and adjusting the freeplay has no effect on the noise. Oil level is to full line - not overfilled.

        As an experiment I put the bike on the center stand and ran the bike with the clutch pulled in. Even with the clutch pulled in there is enough clutch drag to spin the tire in relation to engine speed. Each time I rolled the throttle on-off the click/clunk was very apparent.

        I'm really at a loss about this noise - it offends my mechanical sympathy. Any suggestions appreciated.
        Sounds to me like a loose or worn out chain slapping around. Maybe the chain is smacking the shift shaft when you accell or decell?

        Comment


          #5
          Check both sprockets are securely tightened and the condition and tension of your chain. You shouldn't have any transmission gremlins after only 700miles of operation.
          :) The road to hell is paved with good intentions......................................

          GS 850GN JE 894 10.5-1 pistons, Barnett Clutch, C-W 4-1, B-B MPD Ignition, Progressive suspension, Sport Demons. Sold
          GS 850GT JE 1023 11-1 pistons. Sold
          GS1150ES3 stock, V&H 4-1. Sold
          GS1100GD, future resto project. Sold

          http://i155.photobucket.com/albums/s...s/P1000001.jpg
          http://i155.photobucket.com/albums/s...s/P1000581.jpg

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            #6
            Clutch gremlins

            For a while my bike would feel like something was grabbing when I was about 30 ft from stopping with the clutch disengaged. I pulled the cluch pack to check the basket for wear and found no problem. When I put the plates back in I rotated each one a couple of notches and now it works better than when the clutch was new. I don't know how or why it worked but ya gotta like these type of cures.

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