HELP! Clutch or Spline Issue I think.

[jchaplick21]

Hello all,

I am new to the forum and new to bikes and new to GS bikes. So just plain new in general.

I need help. I just bought an 81 Suzuki GS650GL that needs some work. Its in great shape, and it runs and has low miles. The issue I have is that while it shifts positively into each gear and runs, the engine is free revving. It feels sort of like a clutch issue but Ive also read about the rear splines being stripped as well. If you run it in gear with the back wheel lifted the back wheel spins, and if you squeeze the driveshaft boot you can feel the drive shaft spinning. But if the bike is on the ground it wont move when in gear. The bike was driven last year quite often and the issue started suddenly.

Does anyone have any ideas as to what this could be?

[Steve]

If you run it in gear with the back wheel lifted the back wheel spins, and if you squeeze the driveshaft boot you can feel the drive shaft spinning. But if the bike is on the ground it wont move when in gear.

What happens when you try to run it with the wheel on the ground?

Obviously you will need a helper, but see if the driveshaft is turning. If it is, bet on the splines being bad.

.

[tom203]

"If you run it in gear with the back wheel lifted the back wheel spins, and if you squeeze the driveshaft boot you can feel the drive shaft spinning. "

What happens to boot " feel" if you apply the rear brake - and are there any odd unpleasant noises?

[bwringer]

Seems simplest to remove the rear wheel and look...

[tkent02]

Very simple, and it sure sounds like the splines, but I didn't think the 650s had spline issues? Maybe someone tried too many burnouts or wheelies or something.

[bwringer]

Yep, the 650s definitely could suffer from the same "soft spline" issues. If it's a later '81, it definitely could have had the soft "gold" spline.

The spline is the exact same part, and it wears out more from miles than from abuse. The metal just wasn't hardened properly for this usage.

[tkent02]

The spline is the exact same part, and it wears out more from miles than from abuse.

It's the same?? I thought everything in there was smaller.

[bwringer]

It's the same?? I thought everything in there was smaller.

The final drive (the "pumpkin") is different, but the driven spline coupler in the wheel is the same part.

[jchaplick21]

What happens when you try to run it with the wheel on the ground?

Obviously you will need a helper, but see if the driveshaft is turning. If it is, bet on the splines being bad.

.

The bike will roll while in gear if I push it along the ground. Also the drive shaft does turn when it's running.

I haven't really noticed any unpleasant noises.

I suppose I should just take the rear wheel off and check haha

[jchaplick21]

Ok, so now I've tried a bunch of things and I'm back to thinking it's the clutch. There is no disconnect between the rear wheel and the drive shaft.

with the bike on the center stand, I can put the bike in gear without even using the clutch. And it makes the back wheel spin. If I pull the clutch it takes a couple seconds for it to disengage, not just the wheel to stop free spinning, but actually disengage. (This is easier to tell when it's on the ground) when you give it throttle you can even stop the back wheel and the drive shaft from spinning with your hands, it feels like it's trying to grab but it can't.

Does this sound like the clutch to you guys?

Please let let me know

[Steve]

You are saying that the clutch does not grab hard enough to drive the bike?

The first thing I would check is adjustment, to make sure the cable (and any other linkage) is not keeping pressure on.

.

[jchaplick21]

You are saying that the clutch does not grab hard enough to drive the bike?

The first thing I would check is adjustment, to make sure the cable (and any other linkage) is not keeping pressure on.

.

the clutch arm moves, and returns. What else is there to check?

Im pretty much a beginner at this, so explain things the best you can. I appreciate it greatly.

[Steve]

The clutch arm may move, but is all tension taken off the cable? When you are not pulling on the clutch lever, there should be some slack on the cable. The lever should be free to jiggle a little. I think the manual calls for about 2mm of clearance between the lever and the housing, up near the pivot point. If there is no play there, it's possible that everything is simply too tight, which prevents the springs from pushing on the disks properly.

Where on this big blue marble do you call "home"? Someone might be close enough to stop by and help.

Feel free to take a few moments to update your profile to show your location and your bike, so we don't have to ask.

.

[jchaplick21]

It may not be. I'm going to try right now.granted I can't turn the bike on but it's worth a shot.

I am in seaside nj.

[tom203]

If cable appears somewhat correct,it might be time to pull clutch cover off. The rack system could be jammed -see parts layout

http://www.alpha-sports.com/spst/1981%20GS650G/06.htm?q=suzuki-parts