• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Clutch Cover Fitment

  • Thread starter Thread starter pontiacstogo
  • Start date Start date
P

pontiacstogo

Guest
I purchased a clean, used replacement clutch cover for my 82 GS1000SZ as the one that was on there was beyond restoration.

It arrived bare without the clutch actuating rod, so I managed to drive out the old shaft and install it into the new cover.

I fitted the two dowels in the cases, and installed a new gasket. I expected to just be able to slip the cover on and have it seat flush with the cases, but that wasn't what happened. It felt like it was bottoming out on the center rod from the clutch i.e. there was a gap between the cover and cases on one side or the other (depending on where I pushed).

I removed the cover and measured it sixty ways to Sunday and it seems to be identical to the one I'm replacing.

Eventually, I threaded in the bolts and gradually snugged the cover up to the cases by tightening in an opposite sequence. Everything seems to be fine - I refitted the clutch lever on the spline and was able to rotate it with a pipe extension i.e. the clutch operation feels normal (can't tell for sure because the engine is out of the bike).

Is this OK or is there something not right?
 
Sounds ok

The teeth on the clutch rods just had to meash
 
The gears on the shaft coming out of the basket should face left. Turn the gear in the cover into the gear on the basket. This should pull the cover towards the engine. You can always take off the clutch cable lever and put it on the right teeth on the splines.
 
Yep - I had no trouble meshing the gears and I had the clutch arm off the splines while I was fitting the cover.

My problem started when the mating surfaces were about 2mm apart from each other. If I tapped one side flush with a rubber mallet the other side would open up to around 4mm and vica versa.

It really seemed as if the rod coming out of the basket was 'bottoming' on the inside of the cover. I could slip the old cover on and it would mate up flush to the cases with no problem - but of course it had the clutch arm shaft out of it at that point.

I hope everything's OK :confused:
 
That's not right. The clutch cover should sit flush with the engine case after the gears have meshed. How is the clutch actuator going to pull the clutch out to seperate the plates if the pull out gear is bottoming out before you even work the clutch cable?
Check where the pull out rod has the same depth to enter each cover. Sounds like you got the wrong cover.
 
Last edited:
Just got back in from taking another look at it (cause it was bugging the hell out of me).

I've worked out that it's not the clutch rod bottoming out. Instead, it's binding at the front of the cover. It's not much, but it's enough to try and push the cover rearwards such that it doesn't want to go on the dowels cleanly. I found this out by removing both dowels, then fitting the cover up - it fitted flush with no problems.

I'm going to try removing a bit of material at the front of the cover tomorrow to see if I can correct it.
 
OK - an update....

I somehow have the wrong clutch cover. After starting the bike, I noticed a small oil drip at the front of the clutch cover that would run down the cases and drip off the bottom. Only after the bike was running but it had to be fixed. So off with the exhaust, drain the brand new oil and remove the cover.

ClutchCover001.jpg


Here's the gasket on the original Katana cover;

ClutchCover004.jpg


Here's the gasket on the replacement cover;

ClutchCover005.jpg


Notice that the gasket does not even cover the leading edge of the cover. It's not like a different gasket or sealer is going to fix this problem either as the two mating surfaces (cases and cover) don't line up. I was told this cover was from a GSX1100S but I don't know that for sure.

Either way, I need to find a clutch cover for a GS1000SZ.
 
You must log in or register to reply here.
Back
Top