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GS1100 Clutch troubles

  • Thread starter Thread starter DFWSpeedster
  • Start date Start date
D

DFWSpeedster

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I have a 1980 GS1100E that I just purchased. I replaced the leaking clutch cover gasket, put it back on, and now I can't get the clutch to fully engage. No matter how tight the cable is, I can't seem to get it all the way engaged, the wheel still spins in first gear with the clutch in! I'd say its about 60% engaged when the lever is pulled back all the way.

In relation to the cable itself, should the clutch release arm be at a slight angle while being parallel to the clutch cover? I couldn't find anything that specifies the position of it online or in the shop manual.
 
bonanzadave said:
That sounds like your issue. Pull the arm off the splined shaft again and move it one tooth.
Click to expand...

One tooth in which direction? Should the arm be parallel to the cover? I can't find a picture of how it should look
 
The arms are usually always pointing out a bit. If you grab the arm you'll notice you can actually push it in towards the engine a bit before you can feel any pressure against it. So basically you want it to connect to the cable just before that point of pressure. A bit of playing around with it and you'll have the right spot then you can fine adjust your cable.
 
Your cable could be bad,but also if the steel plates in your clutch are warped it could cause that,too.
 
Was it working fine before? if so then your cable and clutch are just fine, you just need to find the 'sweet' spot with the arm and cable.
 
Well, I removed the cable from the arm, and manually moved it from the starting position to the final position, and the wheel still rotates even though the clutch should be engaged. I'm thinking now it could be a problem with the clutch springs? I can't imagine a clutch with only 20k miles on it going bad.
 
I took off the clutch cover, and the whole clutch basket is "loose". There are many metal shavings from where the basket was making contact with the inside of the block. I point it out 0:15 into the video.

http://youtu.be/_g_ph4oNTb8

I forgot to mention that the bike hasn't been ridden in 20 years. I just removed the clutch plates and, judging by how stuck together they were, I believe that could be the reason that the clutch is dragging. I'll coat the plates individually in fresh oil, reassemble, and see if the clutch stops dragging.
 
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The aluminum shavings you see were probably cause from improper placement of one of the clutch cover bolts. It looks like the hub has been shaved down a bit on the outer edge in the video. This is caused when the longest clutch cover bolt is placed into the wrong hole. If you look at the bolt hole 15 seconds into the vidio you can see how a bolt going to far thru the threads will hit the hub.
 
Last edited:
zuzu said:
The aluminum shavings you see were probably cause from improper placement of one of the clutch cover bolts. It looks like the hub has been shaved down a bit on the outer edge in the video. This is caused when the longest clutch cover bolt is placed into the wrong hole. If you look at the bolt hole 15 seconds into the vidio you can see how a bolt going to far thru the threads will hit the hub.
Click to expand...

I guess I should watch how many beers I have before diving into this. Yikes! Sure enough, I buttoned it all up (sober) and no noise whatsoever!
 
I reassembled the oiled clutch plates, measured them and the springs (they were all within factory spec) and the damn thing STILL drags! I guess I'll look into new plates
 
That clutch basket is wasted. It should not wobble that much. The gear is not moving as much as the basket. Backing plate and rivets are shot.
 
I haven't seen any clutches falling apart like that. Ever.

Getting the whole basket rebuilt is common on the big GSes, not that expensive. It will be far better then new afterwards.

I bet that one may be too wasted to rebuild.

I'd be real worried about how far into the engine and especially the transmission the swarf went. Splitting the cases to clean it all out might not be a bad idea.
 
tkent02 said:
I'd be real worried about how far into the engine and especially the transmission the swarf went.
Click to expand...

When my starter clutch chewed on my crankshaft I picked up a bunch of that metal in the oil filter. I also filled up the crank case with mineral spirits and flushed it out. I hope I got most of it.
 
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