Tranny/Shifting problem

[rustybronco]

Then the question that begs to be asked, is the cable stretching? measure the length of travel of the cable on the clutch handle side and the clutch lever side, should be the same.

can you shift into any other gears with the engine off and on the center stand. you may have to rotate the rear tire a little bit to get it go into gear.

on the center stand, with the engine running and in 1st gear at say 3,000 rpm, pull up on the shift lever, the back off the throttle, did it go into 2nd? ( don't let it off the center stand please!)

[ALB80-850]

The cable doesn't appear to be streching. Will not shift while running, will not shift while off, either. I removed the clutch arm to operate it manually, feels like there is nothing there, no restance at all. Also moving the shift lever manually, also feels like nothing there. Did manual operation with engin off, as well as running.
Should the pinion shaft spin freely? Or only turn a 1/4 turn or so? Mine only turns a 1/4 turn.

Andy

[chef1366]

I had hoped it was something simple. Now you need to take the clutch hub off and have a looksy at the shifter forks.

[Killer2600]

The cable doesn't appear to be streching. Will not shift while running, will not shift while off, either. I removed the clutch arm to operate it manually, feels like there is nothing there, no restance at all. Also moving the shift lever manually, also feels like nothing there. Did manual operation with engin off, as well as running.
Should the pinion shaft spin freely? Or only turn a 1/4 turn or so? Mine only turns a 1/4 turn.

Andy

You shifted into 1st according to your post so how can the shift lever feel like nothing is there?

I'm guessing you don't have the clutch cable, arm, and/or pull rod set right and aren't disengaging the clutch.

[psyguy]

with the engine off, you should be able to shift through all gears back and forth (start from neutral, or if in 1st gear - rotate the back wheeel a little so it goes into the neutral easily
if you cant shift like this it's most likely a shifter mechanism prob

but is does also sound like your clutch isnt operating properly
make sure everything is back together as per the parts diagram and the centre nut is tight
it would pay to measure the plates and the springs to see if they are in spec

hopefully you have only one of these probs and not both!

[ALB80-850]

Aside from 1st gear, it feels like nothings there.

Everything is on the low to mid end, but all within spec.

Will attempt to hand shift, but plan on pulling the clutch hub and check the shift fork.

My computer is down. Have to use my fathers, which is a pain in the a--!Will post the results soon-ly. Maybe pictures if needed. Thasnks for all the suggestions and help.

Andy

[ALB80-850]

OK, I fianlly got a chance to pull the whole clutch assembly. I think I solved the problem, but would like some input before I re-assemble the whole thing.

1st off, after pulling the clutch assy, everything looked ok. I looked in the manual and tried to compare pictures of the inner workings and noticed my shifting fork was in the wrong position(off by 1 or 2 teeth) I then removed the shift lever and slid the shaft to the right side of the bike and repositioned the shifting fork up 1 or 2 teeth and re-engaged it with the little dog it meshes with and slid the shaft back to the left, the reinstalled the sfift lever. I then turned on the key and was able to shift thru all the gears(having to move the rear wheel a little).

Does this sound like problem solved? I would like any input before re-assembly and trial.

Thanks,

Andy

P.S. no pictures, I think this was the problem and didn't feel the need. I could still take some if needed. Just ask.

[chef1366]

From not being there I would say give it a shot!
Hope it is that easy

[psyguy]

indeed, sounds like a problem solved

that dog can be a dog to put in the right place (pun intended)
i played with it for a while when i had the engine disasembled on the bench, before i was confident i was putting it back the correct way

[ALB80-850]

Well, every thing is back together. I also swaped the carbs for a better set. No fine tuning has been done yet, but she is running real smooth.

The problem still remains. I can shift thru all gears without problem. I still however, release the clutch without the bike lurching and stalling. I also cannot start it in gear with the clutch lever depressed. I have tried to adjust the cable, with no success. Not sure what to do next. The only thought I have is the clutch plate and fiber behind the piano wire keeper my be stuck. I didn't pull these when I had the clutch apart. The manual recomends to replace the wire each time you remove it and I didn't want to order just that part and have to waite for it.

Anybody have any ideas??

Andy

[bonanzadave]

The manual recomends to replace the wire each time you remove it and I didn't want to order just that part and have to waite for it.

Mine dont have no stinkin wire. Seems to work fine. Heres some pics. Maybe they will shed some light on something.

http://www.thegsresources.com/_forum/showthread.php?t=125593&highlight=clutch+overhaul

[chef1366]

Take off the clutch cover. Take out the fibers and steels. With the bike in neutral the middle clutch hub should turn easily. If not you pinched the bearings or installed it wrong.
Hope this helps

[psyguy]

so, when on the centrestand and the engine running, you pull the clutch in and shift into 1st gear - and with the clutch pulled in the wheel keeps spinning?
unless you instaled something incorrectly at the clutch assembly or are missing some parts i would suspect the clutch cable
(or the clutch actuating rod and/or lever being positioned incorrectly)

[ALB80-850]

With the steels & fibers removed the inner hub spins like a top! I can't be 100% sure, due to the fact that I never pulled the clutch apart before, but the whole assembly went back together as it was taken apart. No parts bound up or were forced back into position. The whole process seemed quite easy and I did follw the pictures in the Suzuki manual.
I have read several post that talk about weak clutch springs. Could mine be to strong or over torqued? I did measure them while I had them out and they were within spec, on the low end. Im pretty sure this is going to be a simple matter to fix. Probably is the cable or actuator arm mis-aligned. It is real frustrating. I have tried to adjust the clutch cable from one extreme to the other looking for the sweet spot or at least something a little better to let know Im heading in the right direction, without success. All tips and suggestions are welcome and appreciated, thanks.

Andy

[TheCafeKid]

With the steels & fibers removed the inner hub spins like a top! I can't be 100% sure, due to the fact that I never pulled the clutch apart before, but the whole assembly went back together as it was taken apart. No parts bound up or were forced back into position. The whole process seemed quite easy and I did follw the pictures in the Suzuki manual.
I have read several post that talk about weak clutch springs. Could mine be to strong or over torqued? I did measure them while I had them out and they were within spec, on the low end. Im pretty sure this is going to be a simple matter to fix. Probably is the cable or actuator arm mis-aligned. It is real frustrating. I have tried to adjust the clutch cable from one extreme to the other looking for the sweet spot or at least something a little better to let know Im heading in the right direction, without success. All tips and suggestions are welcome and appreciated, thanks.

Andy

Andy, you have a pic of your actuator arm and what not assembled? Id like to see it. Sometimes you have to cock that arm back around from where it was. I seem to remember mine being in a little different position than it is now before the springs were changed in my 1100G.