Can't seem to shift - GS850GL

[jdion81]

While trying to check the wiring to be sure everything was correct during the rebuild I lifted pulled the clutch and lifted the shift lever. The engine has not been started yet, and there is no fluid in the engine, no oil and no gear oil. When I pulled the shift lever it took more effort than normal (but not a lot) to get it to crunch/clunk into gear. I wanted to check the gear position indicator and tried to shift to another gear, but I cannot.

Right now the Neutral light is lit on the dash and I cannot shift to another gear while pulling the clutch. Any ideas on what to check, or if not being able to shift without running and no fluids would cause me to not be able to shift?

I thought maybe the clutch cable may need adjusted, I have over adjusted it to get more pull than needed to test that its the clutch not pulling enough. Still no change.

[roeme]

On a 550, there are three different points were the clutch actuation mechanism can be adjusted (both ends of the clutch cable and the worm drive in front of the pushrod), but I'm not sure about your model.

The symptoms you describe are almost the same I encountered when the third adjustment screw rattled loose.

[jdion81]

Are you saying there is a adjustment for the clutch inside the clutch cover?

[roeme]

Are you saying there is a adjustment for the clutch inside the clutch cover?

No, I'm saying there's one on the 550's. Stick your nose in the manual/parts drawing of your model, maybe there is one as well...or wait until someone of the old farts passes through

[roeme]

No, I'm saying there's one on the 550's. Stick your nose in the manual/parts drawing of your model, maybe there is one as well...or wait until someone of the old farts passes through

https://www.suzukipartshouse.com/oem...8b4e64c/clutch

Part 28 on the clutch drawing. Surely you have tried to put the lever one notch further than it is currently...? (Or is that impossible?)

Also, our Library seems to missing a 850 Service manual.

[jsandidge]

Also, our Library seems to missing a 850 Service manual.

I almost missed that the other day too. It's actually on top of the block of all the other manuals.

[jdion81]

I got the manual and all of the parts drawings. Unfortunately it wasn't a clutch adjustment issue, I found what it is. I think I have it resolved. It was this thing a jig:

IMG_20180219_194917.jpg

[jdion81]

I got the manual and all of the parts drawings. Unfortunately it wasn't a clutch adjustment issue, I found what it is. I think I have it resolved. It was this thing a jig:

IMG_20180219_194917.jpg

When I had the clutch cover off, it slid out of alignment and was too far in the low position.

[jdion81]

I removed the gear shift lever and was able to slide the shaft towards the clutch side of the engine and realign the teeth on the gear shift piece that was pictured above. I'm able to shift easily from neutral to second gear, but it takes a little effort to get it in the first first gear. I have to slightly pull up on the lever and then quickly press it down to get it to shift to First. I'm not be able to get it to shift into 3rd or above.

[tom203]

I'd pull the clutch assembly off and look at how shift mechanism should be setup

image.jpg

[jdion81]

I just pulled the cover and using an inspection mirror found that I was off by one tooth on the gear shift lever where it meshes with the other gear that moves the pawls. I'm sorry I don't know what the part name is. I'm able to shift from 1st gear to neutral and then the second easily now but can't seem to go any higher than 2nd gear. I still have no fluid in the engine, do you think this could be causing my issue?

[2BRacing]

Try moving the rear wheel back and forth a bit while trying to move the shifter into higher gears.

[jdion81]

Yep, wiggling the wheel allowed me to shift up and down. But now it seems the clutch isn't engaging. Turning the wheel while the bike is in gear turns the engine. I need to figure that out, hopefully just an issue of adjusting the clutch.

[tom203]

"But now it seems the clutch isn't engaging"

Assuming you meant disengaging... the clutch will still have lots of drag ,especially when it's cold and unlubricated. So,yes, cable probably just needs adjustment